Maeda MC-305C-2 Operation Manual
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Maeda MC-305C-2 Operation Manual

Mini-crawler crane
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OPERATION MANUAL
MINI-CRAWLER CRANE
Serial No. D0338 and up
Unsafe use of this machine may cause serious injury or death. Operators
must read this manual before operating this machine. This manual should
be kept near the machine for reference and periodically reviewed by all
personnel who will come into contact with it.
MAEDA has Operation Manual written in some other languages. If a foreign
language manual is necessary, contact your local distributor for availability.
NOTICE
103E-OM1805-08

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Summary of Contents for Maeda MC-305C-2

  • Page 1 NOTICE MAEDA has Operation Manual written in some other languages. If a foreign language manual is necessary, contact your local distributor for availability.

  • Page 3: Table Of Contents

    CONTENTS ITEM Page INTRODUCTION 1- 1 1. INTRODUCTION 1- 2 2.FOR SAFE USE OF MACHINE 1- 3 3. MACHINE OVERVIEW 1- 4 3.1 SPECIFIED OPERATIONS 1- 4 3.2 MACHINE CONFIGURATION 1- 4 3.3 MACHINE FUNCTIONS 1- 5 4. QUALIFICATION FOR OPERATION 1- 6 4.1 QUALIFICATION FOR CRANE OPERATION 1- 6...

  • Page 4: Item Page

    ITEM Page 1.6.3 MOMENT LIMITER OPERATIONS 3-20 1.6.4 NAMES OF MOMENT LIMITER DISPLAY UNIT 3-22 1.6.5 MOMENT LIMITER FUNCTIONS 3-29 1.6.6 MOMENT LIMITER STARTING STATUS 3-31 1.6.7 MOMENT LIMITER WORKING ENVELOPE SETTING 3-32 1.6.8 EMERGENCY STOP CANCEL SWITCH 3-33 1.6.9 MOMENT LIMITER ERROR CAUSES AND ACTIONS TO BE TAKEN 3-34 1.7 OVER HOIST DETECTOR 3-35...
  • Page 5 ITEM Page 3. HANDLING RUBBER TRACKS 3-102 3.1 GOOD USE 3-102 3.2 WARRANTY 3-102 3.3 DOS AND DON’TS 3-103 3.4 CAUTIONS IN USING RUBBER TRACKS 3-104 4. HANDLING WIRE ROPES 3-106 4.1 BENCH MARK FOR REPLACING WIRE ROPES 3-106 4.2 What TO DO WITH TWISTED WINCH WIRE ROPE 3-107 5.
  • Page 6 ITEM Page 8.7 MAINTENANCE EVERY 50 HOURS 4-24 8.8 MAINTENANCE EVERY 250 HOURS 4-28 8.9 MAINTENANCE EVERY 500 HOURS 4-32 8.10 MAINTENANCE EVERY 1000 HOURS 4-36 8.11 MAINTENANCE EVERY 1500 HOURS 4-45 8.12 MAINTENANCE EVERY 2000 HOURS 4-45 SPECIFICATIONS 5- 1 1.
  • Page 7 ITEM Page 8. OPERATION 6-39 8.1 CAUTIONS BEFORE OPERATION 6-39 8.2 OPERATION IN OUTRIGGER MODE 6-40 8.2.1 OUTRIGGER SETTING 6-41 8.2.2 OUTRIGGER STOWAGE 6-42 8.3 OPERATION IN CRANE MODE 6-43 8.3.1 SLEWING OPERATION 6-44 8.3.2 BOOM TELESCOPING 6-44 8.3.3 HOOK RAISING AND LOWERING 6-45 8.3.4 BOOM DERRICKING 6-45...
  • Page 8 ITEM Page SEARCHER HOOK 8- 1 1. SEARCHER HOOK EACH SECTION 8- 2 2. MOMENT LIMITER DISPLAY UNIT 8- 4 3. OPERATION 8- 6 4. INSPECTION AND MAINTENANCE 8- 8 4.1 LEGAL INSPECTION 8- 8 4.2 CONSUMABLES 8- 8 4.3 INSPECTION AND MAINTENANCE LIST 8- 8 4.4 MAINTENANCE PROCEDURES 8- 9...

  • Page 9: Introduction

    INTRODUCTION 1. INTRODUCTION 1- 2 2．FOR SAFE USE OF MACHINE 1- 3 3. MACHINE OVERVIEW 1- 4 4. QUALIFICATION FOR OPERATION 1- 6 5. TERMINOLOGY 1- 7...
  • Page 10 • Keep this manual handy for reference when necessary. • Should you lose or damage this manual, contact Maeda or our sales service agency immediately for ordering a new manual.
  • Page 11 2. FOR SAFE USE OF MACHINE This manual classifies the risks into the following three categories to present the details of the safety labels in easy-to-understand manner. This denotes that there is an imminent hazard which will cause serious personal injury or death. The method of hazard circumvention is stated.

  • Page 12: Machine Overview

    3. MACHINE OVERVIEW 3.1 SPECIFIED OPERATIONS This machine is to be used for operation listed below. • Crane operation This machine is a mobile crane with a rubber track traveling dolly (carrier) mounted with a boom crane. This self-propelled crane is capable of moving (traveling) in the worksite and craning an object weighing within the rated total load.

  • Page 13: Machine Functions

    This machine is composed of the units listed below. [1] TRAVELING DOLLY This is composed of a traveling gear, engine, traveling operation unit, and crane operation unit. [2] CRANE This is composed of a telescoping system, derrick system, hook block, winch system, and outrigger system.

  • Page 14: Qualification For Operation

    4. QUALIFICATION FOR OPERATION • A high incidence of occupational accidents in crane operation has been reported. Be aware that experienced engineers are also no exception. • Warnings and precautions defined in this manual shall be observed for safety assurance during operation of the machine.

  • Page 15: Terminology

    5. TERMINOLOGY 5.1 DEFINITIONS OF TERMS [1] RATED TOTAL LOAD This is the maximum load that can be applied according to a boom length and angle. The load includes the mass (weight) of hoisting accessories (hooks) and slinging ropes. [2] RATED LOAD This is a load derived by subtracting the mass (weight) of hoisting accessories (hooks) and slinging ropes from the rated total load, which is a withstand load for hoisting.

  • Page 16: Diagram Of Working Radius And Lifting Height

    5.2 DIAGRAM OF WORKING RADIUS AND LIFTING HEIGHT ・ The working radius/lifting height diagram indicates the relation between the working radius, boom angle and lifting height above ground of this machine, without any load suspended. ・ “5.575m Boom” in the working radius/lifting height diagram shows the status where one half of first mark is extended from the second stage boom.
  • Page 17 5.3 RATED TOTAL LOAD CHART Rated total load chart is based on level, hard ground. Depending on the outrigger setting or ground conditions, machine may tip over. Rated total load chart is based on working radius with bending of boom and lifted load taken into consideration.
  • Page 18 The rated total load chart provides the maximum loads that the crane is capable of hoisting objects in parallel with the length of the boom. The loads are specified by working radius. [1] BOOM LENGTH The following figures illustrate the condition of the booms, “Boom (1)”, “Boom (1) + (2)”, “Boom (1) + (2) + (3)”, “Boom (1) + (2) + (3) + (4)”, and “Boom (1) + (2) + (3) + (4) +(5)”...
  • Page 19 4. “Boom (1) + (2) + (3) + (4)”: With booms (2) and (3) fully extended, booms (4) and (5) are extended midway (half of the “ mark” passes boom (3)). “Boom (1) + (2) + (3) + (4)” is to apply to crane operation with booms (4) and (5) extended even if only slightly.
  • Page 20 [2] OUTRIGGER MAXIMUM EXTENSION • Make sure all the outriggers are placed properly before performing crane operation. This machine features a safety-interlock system that prevents crane operation unless all the lamps, other than the boom retraction lamp on the outrigger monitor, are on. •...
  • Page 21 [3] OUTRIGGER MIDWAY EXTENSION • Make sure all the outriggers are placed properly before performing crane operation. This machine features a safety-interlock system that prevents crane operation unless all the lamps, other than the boom retraction lamp on the outrigger monitor, are on. •...
  • Page 22 [4] OUTRIGGER MINIMUM EXTENSION • Make sure all the outriggers are extended before performing crane operation. Crane operation is allowed only when all the outriggers are placed properly. Potential overturning of the machine may occur that leads to serious personal injury if disregarded. •...

  • Page 23: Load Indicator

    5.4 LOAD INDICATOR • The following precautions should always be observed when reading the “rated total load” provided by the load indicator. Potential overturning or damage to the machine may occur that leads to a serious accident if disregarded. 1. The outriggers should be placed on a level and firm surface. 2.
  • Page 24 [An example of observation] • The following precautions should always be observed when reading the "rated total load" provided by the load indicator. Potential overturning or damage to the machine may occur that leads to a serious accident if disregarded. 1.

  • Page 25: Safety

    SAFETY 1. BASIC PRECAUTIONS 2- 2 2. DRIVING RELATED PRECAUTIONS 2- 7 3. TRANSPORT PRECAUTIONS 2-21 4. BATTERY HANDLING PRECAUTIONS 2-23 5. MAINTENANCE PRECAUTIONS 2-25 6. SAFETY LABEL LOCATIONS 2-32 7. WEEE DIRECTIVE LABEL LOCATIONS 2-42 All the safety precautions defined in this manual should always be read and observed.

  • Page 26: Basic Precautions

    1. BASIC PRECAUTIONS OBSERVE THE MANUAL AND SAFETY LABELS • Read well and understand this manual as well as the safety labels labeled on various part of this Machine. Attempt to drive/operate without understanding fully may result in wrong operation that may cause personal or equipment accidents.
  • Page 27 USE OF MACHINE THAT WAS RENTED OR PREVIOUSLY USED BY SOMEONE ELSE Check the following subjects on writing before using any Machine that was rented or previously used by someone else. In addition, check the inspection record table for the maintenance conditions such as the periodic inspections.
  • Page 28 TEMPORARY STORAGE WHEN ABNORMALITY IS FOUND WITH MACHINE In case the Machine is found with abnormality and is therefore stored temporarily waiting for service, apply following measures to notify all persons in the office that the use is prohibited due to failure. •...
  • Page 29 SAFETY WHEN REFILLING FUEL • Light petroleum is used as the fuel of this Machine. Do not refill wrong kind of fuel. Refilling wrong oil may damage the engine. • Always stop the engine before refilling fuel. Refilling the oil when engine is driving may cause leaked fuel to draw fire from hot muffler or other substance.
  • Page 30 BEWARE OF ASBESTOS DUST Inhalation air containing asbestos may result in lung cancer. This Machine does not use any asbestos, but asbestos may be contained in the wall, ceiling or other part of construction within the work area of this Machine. In addition, be careful of the followings when working with a material that may be using asbestos.

  • Page 31: Driving Related Precautions

    2. DRIVING RELATED PRECAUTIONS 2.1 BEFORE STARTING ENGINE ESTABLISH SAFETY OF WORKING SITE • Confirm that no danger is present at the working site before starting work. • Investigate the ground and road surface condition of the working site and decide the best working method. •...

  • Page 32: After Starting Engine

    2.2 AFTER STARTING ENGINE INSPECTION AFTER STARTING ENGINE Omitting the inspections after starting the engine results in delay to notice the Machine abnormalities, and may result in bodily accidents and Machine damages. Execute inspection in a wide location with no obstacle. In addition, be sure to prevent people from approaching nearby the Machine.
  • Page 33 CAUTIONS WHEN TRAVELING Always observe followings to prevent serious injuries and death accidents when the Machine is traveling. • Do not attempt looking sideways or other dangerous act when driving. • Do not over speed, start moving sudden, stop sudden, swing sudden or meander since such acts are dangerous.
  • Page 34 BE CAREFUL OF TRIPPING ON UNSTABLE GROUND Always observe followings to prevent serious injuries and death accidents when traveling over an unstable ground for unavoidable reason. • Do not enter soft ground area. The Machine is difficult to evacuate from such area. •...
  • Page 35 CAUTIONS UNDER COLD WEATHER • Remove snow from and defreeze the swing gear, boom and winch related parts, and check the movements before work. • Warm up enough. Attempt to operate the operation levers and switches without enough warm-up causes the Machine to react dull, and may result in unexpected accidents.

  • Page 36: Working With Crane

    2.3 WORKING WITH CRANE INSPECTION BEFORE STARTING WORK Check that the safety devices and crane operate properly. • Operate each of the operation levers and switches under no load, and check that operations take place without abnormality. Repair immediately if any abnormality exists. •...
  • Page 37 CHECK OUTRIGGER PLACEMENT CONDITION Always observe followings to prevent serious injuries and death accidents when placing the outriggers. • When placing the outriggers, always keep the Machine sternly level while looking at the level gauge. Occasionally view the level gauge and make sure to keep the Machine level during the crane works as well.
  • Page 38 BEWARE OF ELECTRICAL CABLE ABOVE • Do not let the Machine contact with electrical cables above. High voltage cables may inflict electrical shock by mere approaching. • Persons who sling are likely to suffer electrical shocks. Always observe followings to prevent accidents. •...
  • Page 39 MEASURES WHEN CHARGE ACCIDENT OCCURS When an electrical charge accident occurred, do not panic but calm down, and apply solution by the following sequence. １. Report Immediately report to the electricity company or related management company, and receive instructions for the power transmission stop, emergency procedures and related. 2.
  • Page 40 PAY ATTENTION TO WEATHER INFORMATION • In case of thunderstorm, risk of lightning exists, so abort working with crane, immediately lower the load and contain the boom. • Exposing the hoisted load to wind causes the load to waggle and causes the Machine to be unstable, thus is dangerous.
  • Page 41 CAUTIONS WHEN SLINGING • Check the following before hoisting a load. Attempt to hoist the load without checking may result in serious bodily accidents by a drop of the load or tripping. • Observe the values in the rated total load chart. •...
  • Page 42 CAUTIONS WHEN WORKING WITH CRANE • Be sure to verify that the emergency stop cancel switch is at OFF (auto) position before operating the crane. Do not attempt the crane operation when the emergency stop cancel switch is at ON (cancel) position. The emergency stop cancel switch is permitted to be at ON (cancel) position only during the inspection or maintenance works.
  • Page 43 CAUTIONS WHEN OPERATING WINCH • Do not let persons enter below the hoisted load. • When hoisting a load, always stop once at the "takeoff" position where the hoisted load leaves the ground. Check subjects such as load stability and load force, then hoist up the load. •...
  • Page 44 CAUTIONS DURING SWING OPERATION • Check the safety in the vicinity and blow the horn before swinging. • If the boom derrick angle is small, be careful to prevent the boom from hitting the driver or the Machine. • Be slow as much as possible when operating the swing lever. Make sure to start smoothly, swing slow, and stop quietly.

  • Page 45: Transport Precautions

    3. TRANSPORT PRECAUTIONS CAUTIONS WHEN LOADING OR UNLOADING • Be especially careful when loading or unloading the Machine because the risks intervene. • Select a location that is level and has firm road surface when loading or unloading the Machine. In addition, keep enough distance from the roadside.
  • Page 46 CAUTIONS WHEN LOADING/UNLOADING WITH CRANE Be careful of the followings when loading or unloading the Machine by hoisting with a crane. • Do Not use those brackets on the boom to hang the whole unit. • Before hoisting the Machine, attach the hoisting brackets (1) (for instance shackles) to the outrigger rotary holes (four), and hang the wire ropes (2) (four) on the hook (3).

  • Page 47: Battery Handling Precautions

    4. BATTERY HANDLING PRECAUTIONS BATTERY HANDLING CAUTIONS The battery fluid includes diluted sulfuric acid, and generates hydrogen gas, and causes bodily accidents and fires if handle improperly, so always observe the followings. • Do not let a cigarette or any fire source approach the battery. •...
  • Page 48 CAUTIONS WHEN CHARGING BATTERY Improper handling when charging the battery may cause the battery to explode. Follow the manuals attached to the Machine and the charger, and always observe the followings. See “Operation 8.3 Cautions in Charging Battery” for details. •...

  • Page 49: Maintenance Precautions

    5. MAINTENANCE PRECAUTIONS 5.1 PRECAUTIONS BEFORE MAINTENANCE FAILURE REPORT Execution of a maintenance not described in our manual may cause unexpected failures. Ask us or our sales service agency for repair. CLEAN BEFORE INSPECTION OR MAINTAIN • Before starting an inspection or maintenance, clean the Machine and prevent rubbish from entering the Machine and make sure the safety will be ensured during maintenance.
  • Page 50 HANDLING ILLUMINATION DEVICES • Use explosion proof illumination device when inspecting with fuel, oil, battery fluid or similar substance. Failure to use explosion proof illumination device may cause leap fire and explosion. • Attempt to work without using illumination device in a dark place may cause injury or other issue.

  • Page 51: Precautions During Maintenance

    5.2 PRECAUTIONS DURING MAINTENANCE NO UNAUTHORIZED PEOPLE Do not admit anyone other than necessary workers during maintenance. And post a guard as necessary. Be especially careful in case of a polishing, welding work, or digging work. MEASURES UPON FINDING ABNORMALITY DURING INSPECTION •...
  • Page 52 CAUTIONS WHEN WORKING ABOVE MACHINE • Tidy the footing to avoid falling and always observe following precautions during maintenance above the Machine. • Do not spill oil or grease. • Do not sprawl the tools. • Beware of the footing when walking. •...
  • Page 53 CAUTIONS DURING WELDING REPAIR Weld in a location with good facility, and, only authorized personnel are permitted to weld. Unauthorized personnel are strictly prohibited since risks such as gas generation, fire and electrical shock are present when welding. The personnel authorized to weld are requested to always observe the followings. •...
  • Page 54 HIGH PRESSURE OIL CAUTIONS Failure to make sure the pneumatic circuit pressure is relieved before inspection or replacement of a high pressure piping or hose may result in bodily accidents. Always observe the followings. • Do not start any inspection or replacement before the pressure dissipates.
  • Page 55 CAUTIONS WHEN TREATING WASTE Always observe the following to prevent pollution environment of the district inhabited with human or animal. • Do not dispose the waste oil down a water system such as sewage or river. • Always drain into a container when draining the oil from the Machine.

  • Page 56: Safety Label Locations

    6. SAFETY LABEL LOCATIONS Keep these labels clean all the time. If lost, apply again or replace with new one. Labels other than the following safety labels exist, treat same. 2-32...
  • Page 57 (1) Footing check （349-4427000） (4 places) (2) Minimum hoist load (103-4551100) (2 places) (3) Loads on 4-rope machine hoisting (4) Outrigger pin hole caution (349-4426900) (103-4551500) (4 places) (5) Fixing bracket position during transportation (6) Machine total weight (103-4551000) (103-4551300) (7) 4-rope machine hoisting position (103-4551700) (8) Boom hoisting bracket caution (103-4553700) (2 places)
  • Page 58 (9) Pinch caution (553-4267600) (10) Winch caution (For winch) (553-4267500) (2 places) (11) Warning (553-4268000) (2 places) (12) Washing caution (350-4539700) (13) Rotating fan caution (349-4526900) (14) High temperature caution (553-4267700) (15) Engine cover caution (349-4427900) (16) High pressure oil caution (349-4427200) 2-34...
  • Page 59 (17) Caution when traveling on slope (349-4421100) (18) Operating caution (349-3195100) 2-35...
  • Page 60 (19) Diagram of working radius and lifting height (103-4550500) (20) Hydraulic oil caution (104-4550800) (21) Radiator caution (349-4427300) (22) Fire ban (349-4427500) (23) Diesel fuel caution (553-4267100) 2-36...
  • Page 61 (24) Rated total load chart (103-3288600) (25) Remote control receiver plug caution (300-4214000) 2-37...
  • Page 62 (26) Precautions for remote control (104-4548800) (27) No access to crane (349-4422000) (28) Welding ground connection caution (349-4527000) (29) High temperature caution (349-4427800) (30) Electric shock caution (553-4267300) (31) Caution when driving, inspecting or maintaining (893-4239100) 2-38...
  • Page 63 (32) Don't swing counterclockwise when fully lowered (33) Spin turn caution (349-4536600) (349-4420700) (34) Exhaust gas caution (349-4427400) (35) Main switch caution (349-4421400) (36) Precaution for crane handling (349-4427100) (37) Slope caution (353-4488600) (38) Caution on emergency stop cancel (553-4266400) 2-39...
  • Page 64 (39) Hook block caution (For hook block) (553-4267400) (2 places) (40) 4-sling hoisting load (103-4550700) (2 places) (41) 2-sling hoisting load (103-4559200) (2 places) (42) Fire extinguisher caution (103-4604800) (43) Fuel tank cap caution (103-4604900) 2-40...
  • Page 65 (44) Precautions for use (portable card) (103-2122800) 2-41...

  • Page 66: Weee Directive Label Locations

    7. WEEE DIRECTIVE LABEL LOCATIONS Keep these labels clean all the time. When replacing electrical equipment on which this label is affixed, always apply a new label. [WEEE DERECTIVE LABEL (104-4549500)] [LOCATIONS OF WEEE DIRECTIVE LABELS] (1) Side of the instrument panel (2) Side of the moment limiter display (3) Lower side of the working status lamp (4) Side of the moment limiter converter...

  • Page 67: Operation

    OPERATION 1. MACHINE EACH SECTION 3- 2 2. OPERATIONS 3-40 3. HANDLING RUBBER TRACKS 3-102 4. HANDLING WIRE ROPES 3-106 5. TRANSPORTATION 3-108 6. HANDLING IN COLD WEATHER 3-111 7. LONG-TERM STORAGE 3-113 8. HANDLING BATTERY 3-114 9. TROUBLESHOOTING 3-119...

  • Page 68: Machine Each Section

    1. MACHINE EACH SECTION 1.1 MACHINE EACH UNIT (1) Boom (15) Moment limiter display unit (2) Boom telescoping cylinder (Inside the boom) (16) Operation seat (3) Boom derricking cylinder (17) Instrument panel (4) Load indicator (18) Hook block (5) Winch (19) Hydraulic oil tank (Inside machinery cover) (6) Post (20) Outrigger un-set warning lamp...

  • Page 69: Traveling And Crane Operation Units

    1.2 TRAVELING AND CRANE OPERATION UNITS (1) Slewing lever (8) Traveling lock lever (2) Boom telescoping lever (9) Right traveling lever (3) Winch lever (10) Left traveling lever (4) Boom derricking lever (11) Moment limiter display panel (5) Outrigger un-set warning lamp (12) Instrument panel (6) Acceleration pedal (13) Outrigger operation panel...
  • Page 70 [1] ACCELERATION PEDAL (6) Use the pedal to adjust the engine speed or output. • Low idling: Release your foot from the pedal. • Full speed: Press down fully on the acceleration pedal. NOTES Press down on the acceleration pedal to the position necessary for the work.
  • Page 71 [6] TRAVELING LOCK LEVER (8) Use this lever to “lock” the traveling levers. • Lock: Push the lever to the right. • Travel: Push the lever to the left. NOTES Operate the traveling lock lever while the left and right traveling levers are at the “NEUTRAL”...

  • Page 72: Instrument Panel Sections

    1.3 INSTRUMENT PANEL SECTIONS (1) Headlight switch (9) Emergency stop cancel switch (2) Crane high-speed switch (10) Fuel gauge (3) Hook stowing switch (11) Hour meter (4) Traveling high-speed switch (12) Pre-heat monitor (5) Boom stowing switch (13) Engine water temperature monitor (6) Horn switch (14) Engine oil pressure monitor (7) Engine emergency stop switch...

  • Page 73: Description Of Each Switches

    1.3.1 DESCRIPTION OF EACH SWITCHES [1] STARTER SWITCH Always turn the starter switch to the “OFF” position after completing the work. NOTES When inserting the key for the starter switch, slide the cover to the left so that you can see the keyhole of the switch, and then insert the key.
  • Page 74 [4] HOOK STOWING SWITCH • The hook stowing switch cancels the auto-stop function of the over hoist detector. Operate the winch lever carefully when stowing the hook block. Pay sufficient attention not to let the hook block collide with the boom. •...
  • Page 75 [7] HORN SWITCH Use this switch to honk the horn. • Honking the horn: Press the switch. NOTES The horn will stop when you release your finger from the switch. [8] ENGINE EMERGENCY STOP SWITCH Use this switch in case of an error in the machine to stop the machine for emergency.

  • Page 76: Description Of Each Monitors

    [10] BOOM LIFT BYPASS SWITCH Use this switch to raise the boom in overload condition. ON : Keep pushing the switch upward. This releases boom raise restriction under overload condition and you can raise the boom. OFF : Release your finger from the switch. The switch returns to the original position and the auto-stop function of boom raise under overload condition will be activated.
  • Page 77 [4] ENGINE WATER TEMPERATURE MONITOR This monitor indicates errors with the engine cooling water temperature. The temperature is normal if this monitor is OFF during the operation. If it lights up during the operation, it means that the engine cooling water temperature exceeded the normal temperature.

  • Page 78: Description Of Fuses

    1.3.3 DESCRIPTION OF FUSES Be sure to turn the starter switch to the “OFF” position when checking or replacing a fuse. CAUTION Fuses protect electrical components and wires from being burnt out. • Fuses are blade fuses. If a fuse was corroded and shows white powder, be sure to change the fuse.

  • Page 79: Outrigger Operation Panel

    1.4 OUTRIGGER OPERATION PANEL (1) Outrigger (1) setting switch (2) Outrigger (2) setting switch (3) Outrigger (3) setting switch (4) Outrigger (4) setting switch (5) Work selector switch (TRAVEL, OUTRIGGER, CRANE) (6) Outrigger (1) extension switch (7) Outrigger (2) extension switch (8) Outrigger (3) extension switch (9) Outrigger (4) extension switch [1] WORK SELECTOR SWITCH (TRAVEL, OUTRIGGER, CRANE)
  • Page 80 NOTES The table below shows the relation between the operation position of the work selector switch and permitted operations. • Only the traveling operation is active when the work selector switch is at the “TRAVEL” position. • When the work selector switch is at the “OUTRIGGER” position, all the devices in the table below are active.

  • Page 81: Outrigger Safety Devices

    1.5 OUTRIGGER SAFETY DEVICES 1.5.1 FUNCTIONS OF OUTRIGGER SAFETY DEVICES The outrigger safety devices have the interlock functions shown in the table below. Interlock Description of Interlock Function Function The outrigger is not enabled if the position pin is not inserted properly by rotating the outrigger rotary to extension side (outward) with the boom being stowed (boom lowered to maximum, slewed and stored).

  • Page 82: Names And Descriptions Of Outrigger Display

    1.5.2 NAMES AND DESCRIPTIONS OF OUTRIGGER DISPLAY (1) Outrigger setting lamp (2) Outrigger extension lamp (3) Boom stowing lamp • Do not remove, disassemble, or repair detection switches. Do not move the detection switches from the original location to another. •...

  • Page 83: Outrigger Un-Set Warning Lamp

    [2] OUTRIGGER SETTING LAMPS The lamp turns on to indicate that the outrigger is set. Turns on when the outrigger tray (3) is set, and turns off when the tray (3) floats (stow). The conditions of the outrigger tray (3) are detected by the detection pin (1) at the tip of the inner box (2) and by the detection switch inside the inner box.

  • Page 84: Moment Limiter (Overload Detector)

    1.6 MOMENT LIMITER (OVERLOAD DETECTOR) 1.6.1 MOMENT LIMITER CONFIGURATION (1) Moment limiter display unit (5) Boom length gauge (inside boom) (2) Emergency stop cancel switch (6) Boom angle gauge (side of boom rear edge) (3) Moment limiter converter (7) Pressure sensor (derrick cylinder) (two) (4) Working status lamp (8) Overwind alarm detector (side of boom tip) (A) Red working status lamp (Warning lamp for...

  • Page 85: Function Of Moment Limiter

    1.6.2 FUNCTION OF MOMENT LIMITER • Do not remove, disassemble, or repair detectors. Do not move the detectors to another location from original position. • Should an object hit a detector or you find any damage on a detector, be sure to verify the actuation status of the auto stop.

  • Page 86: Moment Limiter Operations

    1.6.3 MOMENT LIMITER OPERATIONS The moment limiter is a device for unexpected events. Operations relying on the device will rather incur danger. Pay sufficient attention during the operation not to cause auto-stop of the crane. [1] PROHIBITED ACTIONS AFTER AUTO STOP The following crane operations are prohibited after the crane has stopped automatically due to overloading.
  • Page 87 4. Recovery Operation from Auto Stop The recovery operation from overloading should be the reverse operation of the crane operation that caused the auto stop. Perform one of the followings. (1) Lower the hook and put down the hoisted load on the ground. (2) Retract the boom.

  • Page 88: Names Of Moment Limiter Display Unit

    1.6.4 NAMES OF MOMENT LIMITER DISPLAY UNIT (1) Boom angle display (14) Working radius upper limit switch (2) Lifting height display (15) Working radius upper limit LED (Orange) (3) Boom length display (16) Over un-winding LED (Orange) (4) Boom lifting height upper limit LED (17) Boom angle upper limit switch (Orange) (18) Boom angle upper limit LED (Orange)
  • Page 89 [1] DESCRIPTIONS OF SWITCHES ON MOMENT LIMITER DISPLAY UNIT 1. WIRE FALLS SELECTOR SWITCH AND WIRE FALLS DISPLAY LED (BLUE) When entering the number of wire falls, verify the actually used number of wire falls and make sure to set up correctly. Entering incorrect number of wire falls may prevent issuance of the pre-warnings and boom auto-stop even when the overload is near happening, and thus may result in crane damage or machine trip that may result in serious accidents.
  • Page 90 2. BOOM ANGLE UPPER LIMIT SWITCH AND LED (ORANGE) Use this switch to set or cancel the boom angle upper limit. [SETUP] With no upper limit value being set, set the boom to the angle you would like, and press the switch for 2 seconds. The boom angle at this point is set as the upper limit.
  • Page 91 4. WORKING RADIUS UPPER LIMIT SWITCH AND LED (ORANGE) Use this switch to set or cancel the working radius upper limit. [SETUP] With no upper limit value being set, set the boom to the working radius you would like, and press the switch for 2 seconds. The working radius at this point is set as the upper limit.
  • Page 92 [CANCEL] With the upper limit value being set (LED ON), press the switch for 5 seconds. The current upper limit value setting will be cleared. At the same time, the LED goes off indicating that the upper limit value setting is cleared. NOTES The setting and canceling will not repeat even if you keep the switch pressed for more than 2 seconds.
  • Page 93 [2] DESCRIPTIONS OF MOMENT LIMITER DISPLAY UNIT For LEDs not described in this section, see “Operation 1.6.4 Names of moment limiter display unit”. 1. ACTUAL LOAD DISPLAY SECTION This section constantly displays the actual load of the hoisted load during the crane operation. The actual load indicates the total weight of the hoisted load including rigging and the hook block.
  • Page 94 7. OVER WINDING LED (RED) This LED flashes up when the hook is overwound, and issues overwinding warning and causes an automatic stop. This LED also flashes when the hook is stowed during the hook stowing operation. This is normal. 8.

  • Page 95: Moment Limiter Functions

    1.6.5 MOMENT LIMITER FUNCTIONS [1] OVERLOAD WARNING 1. SAFETY ZONE (“Actual load” is less than 90 % of the “rated total load”) • Green of the working status lamp lights up. • The LED lights up in green if the load factor is less than 90 %.
  • Page 96 [2] WORKING ENVELOPE RESTRICTION WARNING When the working envelope gets close to the set restriction value, a warning is issued to notify the operator and people around of the situation. The last status of the set value for the working envelope restriction is memorized even if the starter switch is turned to the OFF position.

  • Page 97: Moment Limiter Starting Status

    [4] NUMBER OF WIRES SELECTOR SWITCH • Stop the crane operation when changing the number of wires hooked using the number of wires selector switch. Changing the number of wires during the crane operation can cause unexpected accidents. • Perform the crane operation always after matching the number of wires display on the moment limiter and the actual number of wires.

  • Page 98: Moment Limiter Working Envelope Setting

    1.6.7 MOMENT LIMITER WORKING ENVELOPE SETTING • The boom may go beyond the set value when operated at high speed even if the working envelope was restricted by the moment limiter. Be sure to set the working envelope with safe distance from obstacles. Operate the crane at low speed.

  • Page 99: Emergency Stop Cancel Switch

    1.6.8 EMERGENCY STOP CANCEL SWITCH Do not turn ON (cancel) the emergency stop cancel switch unless you find an error or check/perform maintenance on detectors. When turning ON (cancel) the emergency stop cancel switch, always shift the crane speed to low.

  • Page 100: Moment Limiter Error Causes And Actions To Be Taken

    1.6.9 MOMENT LIMITER ERROR CAUSES AND ACTIONS TO BE TAKEN The moment limiter displays an error code at the “rated total load” display section on the display panel to notify the error. If an error code shown in the table below was displayed, contact us or our sales service agency. Error Code Error Details Actions to Be Taken...

  • Page 101: Over Hoist Detector

    1.7 OVER HOIST DETECTOR CAUTION Pay attention to the distance between the hook block and the boom when raising the hook block. The hook block also raises when the boom is extended. Always check the height of the hook block when performing the boom extending operation. (1) Hook block (2) Over hoist detector (3) Weight...

  • Page 102: Operation Seat

    1.8 OPERATION SEAT (1) Back seat (2) Seat (3) Slide adjusting lever (4) Reclining adjusting lever • Adjust the operation seat before driving. Be sure to make adjustment especially after someone else has used it. • Press your back against the back seat of the operation seat and adjust the operation seat so that you can operate the acceleration pedal, control levers and traveling lever without any difficulty.

  • Page 103: Engine Hood

    1.9 ENGINE HOOD • Be sure to stop the engine and remove the starter switch key before opening the engine hood. • Do not open the engine hood immediately after the operation while the engine is still hot. [1] OPENING ENGINE HOOD Open the engine hood with the following procedure when performing inspection/maintenance inside the engine hood.

  • Page 104: Machinery Cover

    1.10 MACHINERY COVER • Be sure to stop the engine and remove the starter switch key before removing the machinery cover. • Do not remove the machinery cover immediately after the operation while the engine is still hot. The machinery cover is large and installed at high position. Be sure to remove/install the cover with two persons or more.
  • Page 105 9. Remove six mounting bolts (7) on the top of the machinery cover (6). 10. Remove two mounting bolts (7) on the left side of the machinery cover (6). 11. Pull up the machinery cover (6) and engine hood (1) together and remove them.

  • Page 106: Operations

    2. OPERATIONS 2.1 CHECKING BEFORE OPERATION 2.1.1 CHECKING BEFORE STARTING ENGINE (VISIBLE CHECKS) • This machine has a diesel engine. If it smells fuel around the engine, the fuel may be leaking. Carefully check the cracks on the fuel hose or fuel hose connections. •...
  • Page 107 [1] CHECKING AROUND CRANE • Look around and below the boom and post and look for any oil leak or similar. Be especially careful to check up the derrick cylinder and lower part of the winch motor near the post. If you find any abnormality, repair.
  • Page 108 [4] CHECKING AROUND OUTRIGGERS • Look below each of the outriggers and check for any oil leak or similar. Be especially careful to check below the outrigger cylinders. If you find any abnormality, repair. • Check each of the rotaries, outriggers, holders and outrigger cylinders for cracks, excessive deformation, contamination and others.

  • Page 109: Checking Before Starting Engine

    2.1.2 CHECKING BEFORE STARTING ENGINE Check the followings in this section without starting the engine and before starting the first work every day. [1] CHECKING/REFILLING ENGINE COOLING WATER Do not check or refill the cooling water with the radiator cap removed. Always check and refill in the reserve tank.
  • Page 110 [2] CHECKING/REFILLING OIL LEVEL IN ENGINE OIL PAN Securely install the oil level gauge and filler cap after checking the oil level and refilling with the oil. If the oil level gauge falls during the operation, the hot oil spouts out of the pan, causing burns.
  • Page 111 [3] CHECKING/REFUELING FUEL LEVEL IN FUEL TANK • Be extremely careful with fire such as cigarette. • Be sure to stop the engine when refueling. If refueling was done with the engine in operation, the fuel spilled on the section where it gets hot such as muffler can catch fire. •...
  • Page 112 [4] CHECKING/CLEANING WATER SEPARATOR • The water separator pot has fuel (diesel oil) inside. Be extremely careful of fire such as cigarette when cleaning the water separator pot. • If the fuel spills when the water separator pot is removed, thoroughly wipe it off. CAUTION •...
  • Page 113 [5] CHECKING/CLEANING FUEL FILTER POT • The fuel filter pot has fuel (diesel oil) inside. Be extremely careful of fire such as cigarette when cleaning the water separator pot. • If the fuel spills when the fuel filter pot is removed, thoroughly wipe it off. CAUTION •...
  • Page 114 [6] CHECKING/REFILLING OIL LEVEL IN HYDRAULIC OIL TANK • The oil may spout out when the cap of the hydraulic oil tank is removed. Turn the cap slowly to let the inner pressure escape before removing. • Do not refill with the oil to the level higher than the “H” (upper limit) of the level gauge. Too much oil may cause the oil to spout out of the air breather during traveling or crane operation, causing burns.
  • Page 115 [7] CHECKING/REFILLING OIL LEVEL IN SLEWING REDUCTION GEAR CASE CAUTION • See “Maintenance 5.1 Use of Lubricating Oil According to Temperature” for which oil to be used. • Use seal tape, etc. at the thread of the filler plug to stop the oil leak and securely tighten the plug after refilling with the oil.
  • Page 116 [8] CHECKING/REFILLING OIL LEVEL IN TRAVELING MOTOR REDUCTION GEAR CASE CAUTION • See “Maintenance 5.1 Use of Lubricating Oil According to Temperature” for which oil to be used. • Use seal tape, etc. at the thread of the oil level check plug to stop the oil leak and securely tighten the plug after refilling with the oil.
  • Page 117 [9] CHECKING/CLEANING RADIATOR AND OIL COOLER FINS The dusts fly in all directions when the compressed air is used. Always wear goggles and mask. CAUTION • To prevent damage on the fins during the use of the compressed air, keep the pressure of the compressed air to 0.20 -0.29 MPa (2 –...
  • Page 118 [10] CHECKING/REFILLING BATTERY ELECTROLYTE LEVEL • The electrolyte generates combustible gas and presents explosion hazard. Do not bring any fire close to the electrolyte. • The electrolyte is a hazardous substance. Avoid contact with eyes or skin. Should it come into the contact with eyes or skin, wash the affected area with plenty of water and consult a physician.
  • Page 119 [11] CHECKING HORN FOR OPERATION 1. Turn the starter switch to the “ON” position and check the followings. 2. Press the horn switch to verify that the horn sounds. If not, the horn may be faulty or the circuit may be open. Ask us or our sales service agency for repair.
  • Page 120 [14] CHECKING OUTRIGGER DISPLAY FOR OPERATION 1. Turn the starter switch to the “ON” position. 2. Operate the work selector switch on the outrigger operation panel to the “OUTRIGGER” position. 3. Verify that the lamps on the outrigger display light up and go off in the order shown below.
  • Page 121 [15] ADJUSTING OPERATION SEAT • Adjust the operation seat before operation or when the operator changes. • Press your back against the back of the operation seat and adjust the seat so that you can fully step on the acceleration pedal. [FORWARD/BACKWARD ADJUSTMENT OF THE SEAT] 1.

  • Page 122: Checking After Starting Engine

    2.1.3 CHECKING AFTER STARTING ENGINE Check the followings in this section after starting the engine and before starting the first work every day. CAUTION The checkups described in this section should be carried out after starting the machine. Refer to "Operation 2.2 Starting Engine" and later to execute the engine startup, traveling operations, outrigger operations and crane operations.
  • Page 123 [TENSION ADJUSTMENT] If the “tension check” of the rubber track found the tension lower than standard tension of the rubber track, make adjustments as described below. Working with the loose rubber track (the tension of the rubber track at 15 mm or more) will cause run-off or early wear of the core metal.
  • Page 124 • TIGHT TENSION (DECREASE TENSION) Inside the rubber track tension adjustment device has the grease sealed. The grease is under high pressure due to the tension of the rubber track. Making adjustments without observing the followings may cause the grease valve to fly away, resulting in serious accidents.
  • Page 125 [2] CHECKING RUBBER TRACKS FOR DAMAGE AND WEAR CAUTION Contact us or our sales service agency for determining whether to replace, repair, or keep the rubber track. The following condition requires the repair or replacement of the rubber track. Ask us or our sales service agency for repair/replacement.
  • Page 126 [3] CHECKING OUTRIGGER SAFETY DEVICE FOR OPERATION [CHECKING OPERATION OF CRANE INTERLOCK FUNCTION] 1. Turn the starter switch to the “ON” position. 2. Operate the work selector switch on the outrigger operation Panel to the “OUTRIGGER” position. 3. Verify that only the boom stowing lamp (1) (green) remains ON on the outrigger display.
  • Page 127 6. Operate one of the four outrigger setting switches (5) to “ON” position and raise the outrigger tray above the ground. 7. Operate the work selector switch on the outrigger operation panel to the “CRANE” position. 8. Operate the crane derricking lever to the “”RAISE” side and verify that the crane does not operate.
  • Page 128 [4] CHECKING OUTRIGGER OPERATION Be sure to refer to "Operation 2.14 Outrigger Setting Operation" and "Operation 2.24 Outrigger Stowing Operation", and strictly observe the methods described and cautions given when checking operations of the outriggers. 1. Verify that the outrigger inner box extends smoothly when the outrigger extension switch is pushed down to the "OUT"...
  • Page 129 [5] CHECKING CRANE OPERATIONS Be sure to set the outriggers by the maximum extension state by referring to " Operation 2.14 Outrigger Setting Operation" before checking the crane operations. Be sure to refer to the Operation sections between "2.15 Cautions before Crane Operation" and "2.23 Crane Stowing Operation", and strictly observe the methods described and cautions given when checking crane operations.
  • Page 130 [6] CHECKING OVER HOIST DETECTOR FOR OPERATION Over hoist the hook block (1), and raise the hook with winch and extend the boom, and verify that the buzzer sounds and an audible message saying "Over hoisted" is spoken, the hook raising operation and boom extending operation stop.
  • Page 131 [8] CHECKING OUTRIGGER EXTENSION POSITIONS Start the engine, execute each of the "MID" and "MAX" outrigger extension operations, and verify that the outrigger display on the moment limiter display section is proper in both case. NOTES Look to the sticker (MID, MAX) affixed to the top of the inner box when adjusting the outrigger extension.

  • Page 132: Starting Engine

    2.2 STARTING ENGINE Verify that there is no one and obstacle around when starting the engine. Honk a horn and start the engine. 2.2.1 NORMAL ENGINE START CAUTION • If it is hard to start the engine due to low ambient temperature, see “Operation 2.2.2 Starting in cold weather”...

  • Page 133: Starting Engine In Cold Weather

    2.2.2 STARTING ENGINE IN COLD WEATHER CAUTION • Do not keep the starter turned for more than 5 seconds. Doing so will accelerate the battery discharge. Wait for about 1 minute before attempting to start the engine again if it did not start. •...

  • Page 134: Operations And Checks After Starting Engine

    2.3 OPERATIONS AND CHECKS AFTER STARTING ENGINE Never refuel (diesel oil) while the engine is in operation. Always stop the engine when refueling. • If any abnormal condition takes place during the warm-up operation, immediately press the engine emergency stop switch to stop the engine for emergency. Then, turn the starter switch to the “OFF”...
  • Page 135 6. Step on the acceleration pedal (6) to the half of the full stroke and operate the engine at medium speed. 7. Operate the boom derricking lever (4) slowly forward/backward and move the derricking cylinder up/down until it reaches the stroke end.

  • Page 136: Breaking-In Machine

    2.4 BREAKING-IN MACHINE Perform breaking-in for the period of about the first 250 hours (hours displayed on the service meter). The life of the machine shortens if overloaded operation or task is performed before the various sections of the machine are used to the operation. While this machine is shipped after thorough adjustment and inspection, forcing the machine from the beginning will quickly degrade the functions of engine and crane, shortening their life.

  • Page 137: Starting Moving Machine

    2.6 STARTING MOVING MACHINE • Do not allow anyone to come around the machine. • Put away all the obstacles on the traveling path. Check for projections and grooves on the traveling path especially when going backward. Fix the traveling path. •...

  • Page 138: Changing Machine Traveling Mode

    2.7 CHANGING MACHINE TRAVELING MODE • Choose the appropriate traveling speed to the ground and road surface conditions while driving the machine. You can operate the traveling levers or choose “high-speed traveling mode” or “low-speed traveling mode” with the operation position of the traveling high-speed switch to change the traveling speed.
  • Page 139 [2] SPIN TURNS • LEFT SPIN TURN Tilt the right traveling lever forward while tilting the left traveling lever toward you to rotate the left and right rubber tracks in the opposite direction for left spin turn. • RIGHT SPIN TURN Tilt the left traveling lever forward while tilting the right traveling lever toward you to rotate the left and right rubber tracks in the opposite direction for right spin turn.

  • Page 140: Stopping/Parking Machine

    2.9 STOPPING/PARKING MACHINE • Avoid sudden stop and try to stop with margin whenever possible. • Choose leveled and solid location for parking the machine. If you park on the slope by necessity, provide some break so that the machine will not move. •...

  • Page 141: Stopping Engine

    2.10 STOPPING ENGINE CAUTION • Stopping the engine before it sufficiently cools down may shorten the life of engine units. Do not stop the engine suddenly except for emergency. • When the engine is overheated, do not stop the engine suddenly. Change the engine speed to low speed, and gradually cool down the engine before stopping the engine.

  • Page 142: Cautions In Driving

    2.12 CAUTIONS IN DRIVING Not observing these cautions in driving will result in serious accidents. [1] CAUTIONS IN DRIVING • When traveling, stow hook and outrigger, and make sure the surrounding safety. • When stowing outriggers, insert each position pins completely to lock.
  • Page 143 [3] CAUTIONS ON UPWARD/DOWNWARD SLOPE • If the machine tilts for “15 degrees” or more forward, backward, leftward, or rightward while traveling, the machine may overturn. Do not travel on the slope of more inclination. • Be sure to switch the traveling high-speed switch to the “OFF” (low speed) position when driving on the slope.

  • Page 144: Description On Outrigger And Crane Safety Devices

    2.13 DESCRIPTION ON OUTRIGGER AND CRANE SAFETY DEVICES Understand well the operation sequence below, warning display from the safety devices under the corresponding machine conditions, and the details of operation stop. Keep these in mind for safe operations. The table below shows what kind of “display and warning” will be issued and the resulting action of the safety devices when this machine is used in the standard condition.
  • Page 145 [3] CRANE OPERATIONS Standard Operation Sequence, Display and Warning Activation of Safety Devices Machine Status • Boom stowing lamp on display panel OFF • Actual work and the rated total load compared, and working status lamp lights up according to the load factor. Moment limiter •...
  • Page 146 [5] OUTRIGGER STOWING OPERATION Standard Operation Sequence, Display and Warning Activation of Safety Devices Machine Status Stow the outriggers. • Setting lamps (red) on display 1. Set and stow the outriggers. panel flash • Work selector switch [Outrigger un-set warning lamp “OUTRIGGER”...
  • Page 147 3-81...

  • Page 148: Outrigger Setting Operation

    2.14 OUTRIGGER SETTING OPERATION • GROUND FOR SETTING OUTRIGGERS Always set the outriggers to the level, safe and solid ground. Performing the crane operation without setting the outriggers can contribute to the overturning of the machine. • OUTRIGGER SAFETY DEVICE Always set the emergency stop cancel switch to the “OFF”...
  • Page 149 • SELECTING LOCATION TO SET OUTRIGGERS • When setting the outriggers on the structural objects such as construction site or concrete floor, verify in advance that the surface where the outriggers will be set has sufficient strength. Insufficient strength in the setting surface will result in overturning or fall of machine due to collapse of the setting surface.

  • Page 150: Name Of Outrigger Components

    2.14.1 NAME OF OUTRIGGER COMPONENTS (1) Position pin (5) Outer box (2) Rotary (6) Inner box (3) Outrigger setting cylinder (7) Outrigger adapter (Tray) (4) Outrigger extension cylinder 2.14.2 OUTRIGGER SETTING OPERATION [1] TASKS TO BE PERFORMED UPON ENGINE STOP There are four outriggers installed to the machine.
  • Page 151 3. Operate the work selector switch on the outrigger operation panel to the ”OUTRIGGER” position. 4. Verify that the boom stowing lamp (1) (green) on the outrigger display is ON. 5. Pull the position pin (1) out of the rotary (2) and rotate the rotary outward.
  • Page 152 [2] TASKS TO BE PERFORMED AFTER STARTING ENGINE The overturning alarm buzzer sounds if the machine tilts for “3 degrees” or more when setting the outriggers. Operate the outrigger switches and adjust the machine to be leveled in which state the alarm buzzer will not sound. 1.
  • Page 153 When operating two outrigger setting switches at the same time, choose two front switches (outrigger (1) and (4)) or two rear switches (outrigger (2) and (3)). Operating two left or right switches at the same time will suddenly raise two outriggers on one side, causing overturning of the machine.

  • Page 154: Cautions Before Crane Operation

    2.15 CAUTIONS BEFORE CRANE OPERATION Not observing these cautions before operation may result in serious accidents. • Verify that the emergency stop cancel switch, boom stowing switch, and hook stowing switch are at the “OFF” position. If these switches are at “ON” position, the operations will not stop. •...

  • Page 155: Operations Before Crane Operations

    2.16 OPERATIONS BEFORE CRANE OPERATIONS CAUTION • Verify that all the lamps on the outrigger display are illuminated in green before performing the crane operation. The crane cannot be operated if any of the four outrigger extension lamps and four outrigger setting lamps is flashing in red. •...

  • Page 156: Crane Operation Posture

    2.17 CRANE OPERATION POSTURE Take the crane operation posture by following the procedure below when switching to the operation from the state described in “2.16 Operations before Crane Operations” in the Operation. 1. Operate the winch lever (3) to the “DOWN” (push forward) side and lower the hook but not to let the hook block touch the ground.

  • Page 157: Hook Raising/Lowering Operation

    2.18 HOOK RAISING/LOWERING OPERATION • With the boom deflection, the hoisted load slightly shifts forward. Notify the workers around such as slinging operators. • If the hook block was hoisted too much, the over hoisting will be detected. The alarm buzzer sounds and the audible message saying “Hook over hoisted”...

  • Page 158: Boom Telescoping Operation

    2.20 BOOM TELESCOPING OPERATION • Operate the boom telescoping lever as slowly as possible. Sudden lever operation especially while hoisting a load will cause the load to swing, giving a great impact to the machine, and thus may break the crane or overturn the machine. •...

  • Page 159: Slewing Operation

    2.21 SLEWING OPERATION • Check the safety around and honk the horn before slewing. • Operate the slewing lever as slowly as possible. Start smoothly, slew at low speed, and stop gently. Sudden lever operation especially while hoisting a load will cause the load to swing, causing the loss of stability in the machine, and thus may break the crane or overturn the machine.

  • Page 160: Crane Stowing Operation

    2.23 CRANE STOWING OPERATION The hook stowing switch cancels the auto stop function of the over hoist detector. Operate the winch lever carefully not to let the hook block hit the boom when stowing the hook block. CAUTION • Stop the swing of the hook block before stowing the hook block. •...
  • Page 161 5. Operate the winch lever (3) to the “UP” (pull toward you) side and winch until the hook block automatically stops (over hoist). NOTES Hoisting the hook block too much will result in the detection of over hoist. Then the alarm buzzer and audible message of “Hook Over Hoist”...

  • Page 162: Outrigger Stowing Operation

    2.24 OUTRIGGER STOWING OPERATION • Do not let people approach toward the machine when stowing the outriggers. Staying around the machine may result in serious accidents such as getting caught between an outrigger and the main unit of the machine. •...
  • Page 163 2. See “Operation 2.2 Starting Engine” and start the engine. 3. Release your foot from the acceleration pedal (6) and change the engine speed to idling. 4. Operate the work selector switch on the outrigger operation panel to the “OUTRIGGER” position. 5.
  • Page 164 9. Verify that the four outrigger setting lamps (3) on the outrigger display are flashing in red. NOTES On the outrigger display, the boom stowing lamp (1) (green) is illuminated and four outrigger extension lamps (2) and four outrigger setting lamps (3) are flashing in red. 10 Push down an outrigger extension switch or two of them at the same time to the “IN”...
  • Page 165 [2] TASKS TO BE PERFORMED UPON ENGINE STOP 1. Pull the position pin (1) out of the rotary (2) and rotate the rotary inward. 2. Insert the position pin (1) to the end at the position where the pin holes are aligned after rotating the rotary (2) inward. NOTES The position pin (1) has a wire to prevent the loss of the pin.

  • Page 166: Dos And Don'ts During Crane Operations

    2.25 DOS AND DON’TS DURING CRANE OPERATIONS • Always set the outriggers on the leveled solid ground when performing the crane operations. • Never perform traveling hoist or the crane operations without setting the outriggers. The machine will be unstable and overturn, leading to serious accidents. •...
  • Page 167 [5] DON’T ACCESS INTO WORKING RADIUS Do not let people access into the working radius such as permitting an operator to go under the hoisted load. [6] DON’T USE FOR OTHER THAN MAIN APPLICATIONS Do not move people up/down with the crane. [7] DON’T PERFORM UNREASONABLE OPERATIONS Operations requiring more than the machine performance can cause accidents.

  • Page 168: Handling Rubber Tracks

    3. HANDLING RUBBER TRACKS 3.1 GOOD USE While the rubber tracks demonstrate many advantages thanks to its performance characteristic to the material, it has a weak point in strength. Therefore, we would like you to sufficiently understand the characteristics of the rubber tracks and to respect don’ts operations and observe the cautions on handling so that the life of the rubber tracks can be extended and its advantages exercised.

  • Page 169: Dos And Don'ts

    3.3 DOS AND DON’TS The following operations are prohibited. • Working and slewing on the ground with broken stones, hard rock ground with great irregularity, reinforcing steels, iron scraps, and near the edge of the steel plates will damage the rubber tracks. •...

  • Page 170: Cautions In Using Rubber Tracks

    3.4 CAUTIONS IN USING RUBBER TRACKS Not observing these cautions in using rubber tracks will cause serious accidents or damage on rubber tracks. Keep the followings in mind during the operation. • Avoid making spin turns on the concrete surface. Sudden steering cause early wear or defect on the rubber tracks.
  • Page 171 • Avoid using the rubber tracks whenever possible depending on the material to be worked on. If you used the rubber tracks on these materials by necessity, wash thoroughly with water after the use. • Avoid the operation on the material crushed and yielding oil (such as soy beans, corns, rape cake, etc.) •...

  • Page 172: Handling Wire Ropes

    4. HANDLING WIRE ROPES 4.1 BENCHMARK FOR REPLACING WIRE ROPES CAUTION • The benchmark for replacing wire ropes is common to all the wire ropes for winching, telescoping the boom, and slinging. • Measure the wire rope diameter at the section where the rope repeatedly passes through the sieve.

  • Page 173: What To Do With Twisted Winch Wire Rope

    4.2 What TO DO WITH TWISTED WINCH WIRE ROPE Be sure to wear a pair of thick leather working gloves when handling wire ropes. CAUTION Change the hooking direction of the wire rope (inverse the hook block side and winch drum side) from time to time to extend the life of the wire rope.

  • Page 174: Transportation

    5. TRANSPORTATION Observe the related laws and regulations and transport the machine safely. 5.1 LOADING/UNLOADING • See "Specifications 1.1 Specification List " in the Dimension for the dimensions and mass of the machine. • Select and use the ramp boards that satisfy the following conditions. •...

  • Page 175: Hoisting Machine

    5.2 HOISTING MACHINE • The hoisting attachments such as wire rope and shackle used in hoisting shall be sufficiently strong for the weight of this machine. • When hoisting the machine, always put the machine in the “traveling posture” and securely insert the four position pins into the rotary of the outriggers.

  • Page 176: Cautions In Loading Machine

    3. Install a shackle (1) to the holes (4 locations) on the outrigger rotaries and hang the hoisting attachments (2) over the hook (3). 4. As soon as the machine leaves the ground, stop and wait until the machine is stabilized. Then slowly hoist the machine. 5.

  • Page 177: Handling In Cold Weather

    6. HANDLING IN COLD WEATHER 6.1 PREPARING FOR LOW TEMPERATURE When the temperature goes down, the machine starts to have some difficulty in starting. Take the following actions. [1] LUBRICATION Change the oil to the one with low viscosity. See “Maintenance 5.1 Use of Lubricating Oil According to Temperature”...
  • Page 178 [4] CAUTIONS AFTER COMPLETING THE OPERATION Observe the followings to prevent the machine from not being able to function the next morning because of deposits such as dirt and water and materials around the feet frozen. • Remove the dirt and water on the machine. Keep the hydraulic cylinder rod surface especially clean to prevent seal from being damaged with the dirt coming into the seal together with the water drops.

  • Page 179: Long-Term Storage

    7. LONG-TERM STORAGE 7.1 BEFORE STORING MACHINE CAUTION The machine shall take the posture shown in the figure on the right during the long-term storage to protect the cylinder rod. See “Operation 2.5 Machine Traveling Posture” for traveling posture. (To prevent rust on the cylinder rod) Store the machine as described below for long-term storage.

  • Page 180: Handling Battery

    8. HANDLING BATTERY Observe the followings when handling the battery. • Stop the engine and turn the main starter switch to the “OFF” position when hecking/handling the battery. • Wipe off the dust accumulated on the top of the battery with moistened cloth. •...

  • Page 181: Removing/Installing Battery

    8.2 REMOVING/INSTALLING BATTERY CAUTION Verify that the battery does not move after securing the battery. If it moves, secure it again. [1] REMOVAL 1. See “Operation 2.14 Outrigger Setting Operation” to rotate the rotary of “outrigger (1)” and “outrigger (2)” outward. 2.

  • Page 182: Cautions In Charging Battery

    8.3 CAUTIONS IN CHARGING BATTERY When charging the battery mounted to the machine • Abnormal voltage may be applied to the alternator, resulting in the breakage. Disconnect the battery terminal wires before charging the battery. • Remove all the fluid plugs to release the gas generated. •...

  • Page 183: Starting Engine With Booster Cable

    8.4 STARTING ENGINE WITH BOOSTER CABLE Start the engine with booster cable as described below. [1] CAUTIONS IN CONNECTING/DISCONNECTING BOOSTER CABLE • Never let the (+) terminal and (-) terminal come into contact with the other when connecting the cable. •...
  • Page 184 [3] STARTING ENGINE Verify that the operation levers are at the “NEUTRAL” position. If the safety lock lever is equipped, also verify that the safety lock lever is at the lock position. 1. Verify that the clips are securely connected to the battery terminals. 2.

  • Page 185: Troubleshooting

    9. TROUBLESHOOTING 9.1 ELECTRICAL COMPONENTS • Make sure that you contact us or our sales service agency for the actions indicated in parentheses in the Actions field. • Ask our sales service agency for repair if you suspect other abnormality or causes than those given below.

  • Page 186: Machine Body

    9.2 MACHINE BODY • Make sure that you contact us or our sales service agency for the actions indicated in parentheses in the Actions field. • Ask our sales service agency for repair if you suspect other abnormality or causes than those given below.

  • Page 187: Engine

    9.3 ENGINE • Make sure that you contact us or our sales service agency for the actions indicated in parentheses in the Actions field. • Ask our sales service agency for repair if you suspect other abnormality or causes than those given below.
  • Page 188 3-122...

  • Page 189: Inspection And Maintenance

    INSPECTION AND MAINTENANCE 1. PRECAUTIONS FOR MAINTENANCE 4- 2 2. BASIC MAINTENANCE 4- 4 3. LEGAL INSPECTION 4- 6 4. CONSUMABLES 4- 6 5. LUBRICATING OIL 4- 7 6. ACCESSORY TOOLS AND STANDARD TIGHTENING TORQUE 4- 8 7. INSPECTION AND MAINTENANCE LIST 4-10 8.

  • Page 190: Precautions For Maintenance

    Always use Maeda genuine parts as specified in the parts catalogue for part replacement. [3] USE PURE GREASE Always use Maeda pure grease. The viscosity of grease must conform to specifications according to ambient temperature. [4] USE CLEAN OIL AND GREASE Always use clean oil, grease, and container to keep impurities out of them.
  • Page 191 • Be sure to clean the electrical parts, especially the starter and alternator, to protect them from dust. [20] DO NOT MIX OIL Never use together with different types of oil under any circumstance. Replace the oil entirely when replenishing a different type of oil. Always use Maeda genuine parts for part replacement.

  • Page 192: Basic Maintenance

    2. BASIC MAINTENANCE [1] OIL HANDLING • Oil is used under extremely harsh conditions (high temperature, high pressure) in the engine and working device, which causes the oil to undergo deterioration with operating time. Always use oil that meets requirements such as grade and operating temperature defined in the operation manual.
  • Page 193 If check finds metal powder on the used filter, c ontact us or our sales service agency . • As to a replacement filter, always unpack it immediately prior to its use. • Always use Maeda genuine filters. [6] COOLANT HANDLING •...

  • Page 194: Legal Inspection

    Consumables such as a filter element and wire rope are to be replaced upon periodic maintenance or prior to the wear limit. Proper replacement of consumables delivers increased economy in machine use. Always use Maeda genuine parts for part replacement. See the parts catalogue for part numbers when ordering parts.

  • Page 195: Lubricating Oil

    5. LUBRICATING OIL 5.1 USE OF LUBRICATING OIL ACCORDING TO TEMPERATURES Use of lubricating oil should vary with changes in temperature. • A specified oil quantity is defined as a total quantity of oil including that for unit piping, and a replacement oil quantity is defined as a quantity of oil to be replaced at inspection and maintenance.

  • Page 196: Accessory Tools

    6. ACCESSORY TOOLS AND STANDARD TIGHTENING TORQUE 6.1 ACCESSORY TOOLS Contact us or our sales service agency to request a tool for inspection and maintenance, when necessary. 6.2 STANDARD TIGHTENING TORQUE LIST Torque the metric bolts and nuts with no specific indication to a values shown in this table.
  • Page 197 [Table 2] [3] Bolt marked with “12.9” (strength [4] Other bolts Nominal Width classification) on its head size across flat Tightening torque {N▪m (kgf▪m)} Tightening torque {N▪m (kgf▪m)} (a; mm) (b; mm) Target value Tolerance Target value Tolerance 13.0 (1.30) 11.1-15.0 (1.11-1.50) 3.0 (0.30) 2.6-3.5 (0.26-0.35)

  • Page 198: Inspection And Maintenance List

    7. INSPECTION AND MAINTENANCE LIST Inspection and maintenance items Page 8.1 INITIAL 10 HOUR MAINTENANCE (Only the first maintenance of a new machine) 4-12 [1] GREASING MACHINE UNITS 4-26 8.2 INITIAL 50 HOUR MAINTENANCE (Only the first maintenance of a new machine) 4-12 [1] REPLACEMENT ENGINE LUBRICATING OIL AND OIL FILTER CARTRIDGE 4-29...
  • Page 199 Inspection and maintenance items Page [6] CHECKING OVER HOIST DETECTOR FOR OPERATION 3-64 [7] CHECKING MOMENT LIMITER FOR OPERATION 3-64 [8] CHECKING OUTRIGGER EXTENSION POSITIONS 3-65 [9] CHECKING ENGINE EXHAUST GAS COLOR, NOISE AND VIBRATION 3-65 4-13 8.5 IRREGULAR MAINTENANCE [1] REPLACEMENT RUBBER TRACK 4-13 [2] REPLACEMENT WINCH WIRE ROPE...

  • Page 200: Maintenance Procedures

    8. MAINTENANCE PROCEDURES 8.1 INITIAL 10 HOUR MAINTENANCE The following maintenance should be performed after 10-hour operation, limited to the first maintenance of a new machine. [1] GREASING MACHINE UNITS See “Maintenance 8.7 Every 50 Hours” for maintenance items and procedure. 8.2 INITIAL 50 HOUR MAINTENANCE The following maintenance should be performed after 50-hour operation, limited to the first maintenance of a new machine.

  • Page 201: Irregular Maintenance

    8.5 IRREGULAR MAINTENANCE [1] REPLACEMENT RUBBER TRACK • The inside of the tension adjusting device of the rubber track is greased. Grease is under high pressure associated with the tension of the rubber track. Failure to follow precautions stated below when removing grease may lead to a serious accident due to the grease valve being popping out.
  • Page 202 [INSTALLATION RUBBER TRACK] • Have a grease gun available. • Have a steel pipe available. 1. See “Operation 2.14 Outrigger Setting Operation” to set the outriggers and raise the rubber track again for about 50mm from the ground. 2. With the rubber track engaged with the sprocket, put the crawler on the idler.
  • Page 203 • Do not use the old wire rope regardless of the frequency of use. • Always use Maeda genuine wire rope. [CRITERIA FOR WINCH WIRE ROPE REPLACEMENT] A wire rope undergoes wear and tear over time.
  • Page 204 [REMOVAL WINCH WIRE ROPE] Use the following procedure to remove the wire rope. 1. Place the machine on a level and firm surface. 2. Place the boom telescoping lever in the “Extend” position (push it toward the front) to extend the boom slightly. 3.
  • Page 205 [INSTALATION WINCH WIRE ROPE] Be sure to attach the rope wedge properly to secure the wire rope. Potential serious accident may occur due to detachment of the wire rope during crane operation if disregarded. CAUTION • Avoid irregular winding of the wire rope in the winch drum. •...
  • Page 206 5. Secure the end of the wire rope (5) to the wedge socket (3), following the procedure provided below. (1) Draw the wire rope (5) through the wedge socket (3) as shown at right. (2) With the rope wedge (7) in position (a), yank at the wire rope (5) in the direction indicated by the arrow.
  • Page 207 [CHECKING BOOM TELESCOPING WIRE ROPE] Prompt adjustment is required if the following event appears in the boom extending wire rope. 1. Retract the boom completely. 2. Remove three mounting bolts (1) at the boom end and remove the cover (2). 3.
  • Page 208 [ADJUSTMENT OF BOOM TELESCOPING WIRE ROPE] CAUTION The wire ropes must be adjusted to the correct tightness. A boom extending wire rope (1 piece) and retracting wire rope (1 piece) are used in this machine. Adjustment of these wire ropes must conform to the specified procedure. Use the following procedure for wire rope adjustment.
  • Page 209 5. Adjustment of boom No.5 extending wire rope (8) (1) Remove the lock bolt (6). Turn the adjusting bolt (9) in the direction that the extending wire rope (8) of boom No.5 becomes tight (clockwise) to provide tightening to the verge of the extension of boom No.5.

  • Page 210: Maintenance Every 30 Hours

    • Be sure to replace the element with a new one after 5 cleanings or a lapse of 1 year from initial use. • Always use Maeda genuine elements. 1. See “Operation 1.9 Engine Hood” and open the engine hood.
  • Page 211 8. Clean the inside of the dust pan (2) and rubber cup (5). 9. Remove the cloth or tape from the air connector at the back of the air cleaner body (4). 10. Insert the cleaned element (3) into the air cleaner body (4). 11.

  • Page 212: Maintenance Every 50 Hours

    8.7 MAINTENANCE EVERY 50 HOURS [1] DRAINING CONTAMINANT WATER/DEPOSITS IN FUEL TANK • Keep from heat and flame, including cigarettes. • Be sure to stop the engine before draining fuel. Potential ignition may occur through spilled fuel if disregarded. • Always put in the fuel tank drain plug and secure it after draining fuel. •...
  • Page 213 [2] DRAINING CONTAMINANT WATER/DEPOSITS IN WATER SEPARATOR • The water separator pot has fuel (diesel oil) inside. Be extremely careful of fire such as cigarette when cleaning the water separator pot. • If the fuel spills when the water separator pot is removed, thoroughly wipe it off. CAUTION Water or dust accumulated inside the water separator pot will cause engine failure.
  • Page 214 [3] GREASING MACHINE UNITS CAUTION • Grease type varies with greasing points. Failure to grease properly may cause the machine to shorten its useful life. See the following table for grease types. • Greasing a new machine is required once every 10 hours until the machine attains the first 100 hours of operation that initial fit emerges.
  • Page 215 4-27...

  • Page 216: Maintenance Every 250 Hours

    8.8 MAINTENANCE EVERY 250 HOURS Perform this maintenance in tandem with maintenance every 30/50 hours. [1] REPLACEMENT ENGINE LUBRICATING OIL AND OIL FILTER CARTRIDGE • The drain plug of the engine oil pan is located directly underneath the machine. Place the outriggers and raise the machine 50mm from the ground for draining engine oil. Insert square timbers between both rubber track and the ground to gain stability for safety assurance.
  • Page 217 4. See “Operation 1.9 Engine Hood” and open the engine hood. 5. Remove the drain plug (P) slowly to drain the oil, keeping from contact with draining oil. 6. Check the drained oil. If check finds a considerable amount of metal powder and foreign objects, contact our sales service agency.
  • Page 218 [2] CHECKING/ADJUSTING ALTERNATOR BELT TENSION [TENSION CHECK] 1. See "1.9 Engine Hood" in the Operation and open the engine hood. 2. With the fingers, push (by approximately 98 N {10kgf}) the midpoint between the fan pulley (2) and alternator pulley (1) of the belt (3), and if the strain is between 10 and 12mm it is within standard.
  • Page 219 [3] CHECKING / REFILLING OIL IN TRAVELING MOTOR REDUCTION GEAR CASE CAUTION • See “Maintenance 5.1 Use of Lubricating Oil According to Temperature” for which oil to be used. • Use seal tape, etc. at the thread of the filler plug to stop the oil leak and securely tighten the plug after refilling with the oil.

  • Page 220: Maintenance Every 500 Hours

    8.9 MAINTENANCE EVERY 500 HOURS Perform this maintenance in tandem with maintenance every 30/50/250 hours. [1] REPLACEMENT FUEL FILTER CARTRIDGE • Keep from heat and flame, including cigarettes, when replacing the fuel filter element. • All the parts will be at elevated temperatures immediately after engine operation, which urges you not to replace the fuel filter element.
  • Page 221 [2] REPLACEMENT HYDRAULIC OIL RETURN FILTER CARTRIDGE • All the parts will be at elevated temperatures immediately after engine operation, which urges you not to replace the filter. Always perform replacement with the engine cold. • Potential gush of oil may occur upon removing the filler cap of the hydraulic oil tank. Be sure to relieve internal pressure by slowly rotating the filler cap before cap removal.
  • Page 222 [3] REPLACEMENT HYDRAULIC OIL SUCTION FILTER • All the parts will be at elevated temperatures immediately after engine operation, which urges you not to replace the filter. Always perform replacement with the engine cold. • Potential gush of oil may occur upon removing the filler cap of the hydraulic oil tank. Be sure to relieve internal pressure by slowly rotating the filler cap before cap removal.
  • Page 223 9. See “Operation 2.1.2 Checking Before Operation” to check the oil level in the hydraulic oil tank. Prompt oil refilling is required if check finds insufficient oil. 10. Install the inspection cover (1), and secure it with the three mounting bolts (2). 11.

  • Page 224: Maintenance Every 1000 Hours

    • Be sure to replace the element with a new one after 5 cleanings or a lapse of 1 year from initial use. • Always use Maeda genuine elements. 1. Place the machine on a level surface. 2. See “Operation 1.9 Engine Hood” and open the engine hood.
  • Page 225 [2] CLEANING ENGINE COOLING SYSTEM • Coolant will be at elevated temperatures immediately after engine operation, which urges you not to drain coolant. Always perform coolant draining with the engine cold. • Do not remove the radiator cap if radiator coolant is hot. Potential gush of boiling water may occur if disregarded.
  • Page 226 4. Turn the radiator cap (5) slowly until it comes into contact with the stopper to relieve internal pressure from the radiator. 5. With no pressure in the radiator, give further turning of the radiator cap (5) until it reaches the stopper while holding it down. Remove the radiator cap (5).
  • Page 227 16. Start the engine with the drain valve (8) open, and ensure the engine runs at low idle. Conduct a cleaning with running water until clean water flows out of the radiator. CAUTION • The radiator is to retain a high water level during cleaning with running water.
  • Page 228 [3] OIL REPLACEMENT IN HYDRAULIC OIL TANK • All the parts will be at elevated temperatures immediately after engine operation, which urges you not to replace oil. Always perform replacement with the oil cold. • Potential gush of oil may occur upon removing the filler cap of the hydraulic oil tank. Be sure to relieve internal pressure by slowly rotating the filler cap before cap removal.
  • Page 229 7. Place a drain pan directly underneath the drain plug (P) to receive drained oil. 8. Remove the drain plug (P) slowly to drain the oil, keeping from contact with draining oil. 9. Check the drained oil. If check finds a considerable amount of metal powder and foreign objects, contact our sales service agency 10.
  • Page 230 [4] OIL REPLACEMENT IN SLEWING REDUCTION GEAR CASE The drain plug of the slewing reduction gear case is located directly underneath the machine. Place the outriggers and raise the machine 50mm from the ground to allow a drain pan to be placed under the machine for draining oil.
  • Page 231 [5] OIL REPLACEMENT IN WINCH REDUCTION GEAR CASE Oil will be at elevated temperatures immediately after engine operation, which urges you not to unplug the inspection port and drain port. Unplug the port with the oil cold. CAUTION • See “Maintenance 5.1 Use of Lubricating Oil According to Temperature” for which oil to be used.
  • Page 232 [6] OIL REPLACEMENT IN TRAVELING MOTOR REDUCTION GEAR CASE CAUTION • See “Maintenance 5.1 Use of Lubricating Oil According to Temperature” for which oil to be used. • Use seal tape, etc. at the thread of the filler plug to stop the oil leak and securely tighten the plug after refilling with the oil.

  • Page 233: Maintenance Every 1500 Hours

    8.11 MAINTENANCE EVERY 1500 HOURS Perform this maintenance in tandem with maintenance every 30/50/250/500/1000 hours. [1] INSPECTION/CLEANING/TESTING FUEL INJECTOR Inspection, cleaning, and test of the fuel injector require special tools. Contact us or our sales service agency to request inspection and repair. [2] CHECKING CRANKCASE BREATHER Crankcase breather inspection requires special tools.
  • Page 234 4-46...

  • Page 235: Specifications

    SPECIFICATIONS 1. SPECIFICATION LIST 2. SPECIFICATION DIMENSIONAL DRAWING 3. DIMENSIONAL DRAWING OF OUTRIGGER WIDTH 4. RATED TOTAL LOAD TABLE 5. WORKING RADIUS AND LIFTING HEIGHT...

  • Page 236: Specification List

    1. SPECIFICATION LIST System / Item MC-305C-2 Machine mass 3900kg Overall length  width  height 4285mm x 1280mm x 1695mm Mass and Distance between idler and 1750mm dimensions sprocket Track gauge 980mm Track width 300mm Maximum rated total load ...
  • Page 237 System / Item MC-305C-2 Model Yanmar 3TNV76 Vertical in-line 3-cylinder, Water cooled, 4-cycle Type (special vortex) Engine Displacement 1.115L (1115cc) Rated output (continuous) 15.2kW/2500min (20.7PS/2500rpm) Fuel tank capacity Light oil/ 40L Battery Model 60B24R (DC12V x 1 piece) Over hoist detector / automatic stop device, three-winding stop alarm / automatic stop device,...

  • Page 238: Specification Dimensional Drawing

    2. SPECIFICATION DIMENSIONAL DRAWING...

  • Page 239: Dimensional Drawing Of Outrigger Width

    3. DIMENSIONAL DRAWING OF OUTRIGGER WIDTH...
  • Page 240 4. RATED TOTAL LOAD CHART [1] RATED TOTAL LOAD CHART AT WIRE ROPE 4 FALLS * The rated total load is a load including the mass of a hoisting accessory (hook: 30kg). OUTRIGGER EXTENDED TO MAXIMUM BOOM (1)+(2) BOOM (1)+(2)+(3) BOOM (1)+(2)+(3)+(4) BOOM (1)+(2)+(3)+(4)+(5) Working...
  • Page 241 [2] RATED TOTAL LOAD CHART AT WIRE ROPE 2 FALLS * The rated total load is a load including the mass of a hoisting accessory (hook: 30kg). OUTRIGGER EXTENDED TO MAXIMUM BOOM (1)+(2) BOOM (1)+(2)+(3) BOOM (1)+(2)+(3)+(4) BOOM (1)+(2)+(3)+(4)+(5) Working Rated total Working Rated total...
  • Page 242 [3] RATED TOTAL LOAD CHART AT WIRE ROPE 1 FALL * The rated total load is a load including the mass of a hoisting accessory (hook: 30kg). OUTRIGGER EXTENDED TO MAXIMUM BOOM (1)+(2) BOOM (1)+(2)+(3) BOOM (1)+(2)+(3)+(4) BOOM (1)+(2)+(3)+(4)+(5) Working Rated total Working Rated total...

  • Page 243: Working Radius And Lifting Height

    5. WORKING RADIUS AND LIFTING HEIGHT...
  • Page 244 5-10...
  • Page 245 INTERACTIVE REMOTE CONTROL 1. OUTLINE OF REMOTE CONTROLLER 6- 2 2. SAFETY PRECAUTIONS 6- 4 3. LOCATIONS OF SAFETY LABELS 6- 8 4. COMPONENTS OF THE TRANSMITTER 6-10 5. COMPONENTS OF THE RECEIVER 6-16 6. SETTING UP OPERATION MODES OF TRANSMITTER 6-20 7.

  • Page 246: Outline Of Remote Controller

    1. OUTLINE OF REMOTE CONTROLLER 1.1 FEATURE This system is designed principally for the following purposes: This Interactive Remote Controller includes both Transmitter and Receiver which facilitate remote control of the Crane which is purchased with this device. This Interactive Remote Controller provides an operation of the Crane at the most convenient place away from it within a range of the length of the connection cable.

  • Page 247: Functions Of Remote Control System

    1.3 FUNCTIONS OF REMOTE CONTROL SYSTEM • The Transmitter allows one hand operation, which enables craning works, such as holding the load by the other hand or slinging, by one person. • The Accelerator lever facilitates the control of the Crane operation speed from stand-by condition to the maximum speed.

  • Page 248: Safety Precautions

    2. SAFETY PRECAUTIONS 2. 1 For Safety Operations NO MODIFICATION ! • Do not attempt to modify or disassemble the Transmitter and Receiver, or the accessories, which may cause an electrical shock or a fire. HOLDING THE TRANSMITTER • The Transmitter is designed for one hand controls in general. Refer to the figure in the right for basic usage of the Transmitter.
  • Page 249 NO SHOCK TO THE TRANSMITTER • During the Transmitter operations, always use a hook belt (1) to prevent the unexpected drop of it. • Always avoide an impact on the Transmitter, such as hitting it to any object. It may result a damage to the enclosure or internal components which may cause a failure or malfunction and brings electrical shock or other serious hazard.

  • Page 250: Precautions For Crane Operation

    2.2 PRECAUTIONS FOR CRANE OPERATION As to the matters to be attended in operation, refer to the section of “SAFETY”, in addition to the following clauses. 2.2.1 PRIOR TO STARTING ENGINE INSPECTION PRIOR TO STARTING ENGINE At the beginning of the day’s operation, perform the opening inspection as specified for this machine, prior to starting the engine.

  • Page 251: Subsequent To Starting Engine

    2.2.2 SUBSEQUENT TO STARTING ENGINE FUNCTION CHECK OF OUTRIGGER MODE BY THE TRANSMITTER, AND NOTICES FOR OPERATION • Switch the operation mode to the “OUTRIGGER MODE” and confirm that the mode is switched correctly. • Activate “Start/Reset button” to assure that the engine correctly starts. •...

  • Page 252: Locations Of Safety Labels

    3. LOCATIONS OF SAFETY LABELS Keep these labels always dirt free. When labels come off, stick them again or replace to new ones. In addition to safety labels shown below, several other labels are requisite. Treat them in the same manner.
  • Page 253 (1) Precautions for remote control (Transmitter) (349-4428500) (2) Precautions for remote control (Receiver) (104-4559400) (3) Remote Control Receiver plug caution (Receiver) (300-4214000)

  • Page 254: Components Of The Transmitter

    4. COMPONENTS OF THE TRANSMITTER (1) LCD Screen (8) Slewing/No.1 Outrigger Operation Lever (2) Start/Reset Button (9) Boom Telescoping/No.2 Outrigger Operation Lever (3) Stop/EMO Button (10) Hook Raising and Lowering/No.3 Outrigger Operation Lever (4) Speed/Mode Button (11) Boom derricking/No.4 Outrigger Operation Lever (5) Hook Stow/Setting Button (12) Accelerator Lever (6) Horn Button...
  • Page 255 [1] LCD SCREEN (1) The LCD screen displays the status of the Transmitter in operation, the established values for each mode, or error messages by symbols, comments or signs. [2] START/RESET BUTTON (2) This button has two usages as below: •...
  • Page 256 [7] POWER SWITCH (7) To push this button switches ON and OFF the power of the Transmitter. Each push will turn ON or OFF alternately. [8] SLEWING/No.1 OUTRIGGER OPERATION LEVER (8) This operation lever functions in two ways as below: 1.
  • Page 257 [10] HOOK RAISING AND LOWERING/No.3 OUTRIGGER OPERATION LEVER (10) This operation lever functions in three ways as below: 1. In the CRANE MODE, this lever controls raising and lowering the hook: • Hook raising: Push the upper end of the lever. •...
  • Page 258 [13] GRIP (13) The Transmitter is designed for one hand controls in general. Levers and buttons can be manipulated by your thumb, while the accelerator lever can be triggered by your forefinger. Other fingers should grab the grip to hold the Transmitter. [14] CONNECTION CABLE (14) The connection cable is a cable between the Transmitter and Receiver.
  • Page 259 6-15...

  • Page 260: Components Of The Receiver

    5. COMPONENTS OF THE RECEIVER 5.1 COMPONENTS OF THE RECEIVER (1) Control Box (3) Monitor Display (2) Main Switch (4) Receptacle CAUTION The remote control system provides flowing safety functions: • Abnormal Signal Detector Circuit When the Main switch of the Receiver is turned ON, this circuit checks the dispatch of crane operations signals for 3 to 4 seconds.
  • Page 261 [1] CONTROL BOX (1) The Control box contains the receiver devices and control devices. Never attempt to dismantle this Control box. [2] MAIN SWITCH (2) The Main switch is a toggle switch to power ON or OFF the Receiver • ON : Turn the toggle to ON to start the Receiver. •...

  • Page 262: Fuse In The Receiver

    5.2 FUSE IN THE RECEIVER • For any tests or replacement of a fuse, always turn OFF the Main switch of the Control box, before removing it. • The fuse must be replaced with the same type of grass tube fuses, and of the same rating. CAUTION A fuse is inserted in the (+) line of the main power supply of the Receiver as a protective circuit of internal devices and prevents circuits from burnt.
  • Page 263 5. With a jeweler’s driver (A) to pull out the fuse (8) from its clips, then examine it. 6. Insert a new fuse or the examined fuse to where the one was. [2] INSERTION OF A FUSE After the fuse is examined or replaced, restore the Receiver in the reverse practice of the removal. CAUTION •...

  • Page 264: A Mode

    6. MODE SETTING OF THE TRANSMITTER This device provides the “A MODE” in which the initial values of the Transmitter are established, the “OUTRIGGER MODE” in which the outriggers are set or stowed, and the “CRANE MODE” where the Crane is operated. This device is designed to switch to the applicable mode for the operation by the Transmitter.
  • Page 265 [1] LCD SCREEN CONTRAST RATIO CAUTION The LCD screen may be illegible when it is set too light or too dark, which may prevent correct operations. Adjust its contrast adequately for comfortable read. Adjust the contrast ratio of the LCD screen: 1.
  • Page 266 [5] OFF TIMER Adjust the Auto shut-OFF time of the Transmitter power. 1. Shift the cursor ( ) using the Hook raising and lowering lever and select the preferred time. The Auto shut-OFF adjust is by 3 steps, 5 min., 10 min., or 15min.
  • Page 267 [9] EXIT CAUTION Once setting-up the desired function items of all is completed, do not forget to practice the termination procedure, below. Otherwise, when this process is not correctly terminated, the latest setting will not become valid. 1. Once setting-up the desired function items of all is completed, ensure that the display has returned to the A MODE screen.

  • Page 268: An Example For Setting In The A Mode

    6.1.3 AN EXAMPLE FOR SETTING IN THE A MODE Hereunder is a procedure to change the time of the “OFF timer”, A MODE SETTING LCD SCREEN from “5 minutes” of the factory setting, to 10 minutes: 1. Use the Hook raising and lowering lever and shift the cursor ( ) to the side of the function item to change.

  • Page 269: Procedure In The Operation Mode

    6.2 PROCEDURE IN THE OPERATION MODE CAUTION When the Main switch of the Receiver is turned ON, its abnormal signal detector automatically starts, first. Please allow it for 3 to 4 seconds, without using any levers, buttons and the Accelerator lever. NOTES •...

  • Page 270: Call Out Outrigger Mode

    6.2.2 CALL OUT OUTRIGGER MODE NOTES The OUTRIGGER MODE consists of “Extension mode”and “Ground setting mode”. Use respective modes as shown below: 1. Push the Power button to turn ON the Transmitter. The “Crane mark” is displayed in the LCD screen for 2 seconds around. NOTES In case that the power is already ON, once turn OFF, and then push the Power button again for power 2.
  • Page 271 4. The operation mode is already switched to the “OUTRIGGER MODE”, thus the “Outrigger mark” is exhibited. Soon after, it enters into “Ground setting mode”, then the mark turns to “Ground setting ( )“. 5. To shift to “Extension mode”, push the Speed/Mode button, while the LCD screen shows the “Ground setting mode”.

  • Page 272: Checking Before Operation

    7. CHECKING BEFORE OPERATION Precautions shown in this section must be practiced prior to the day’s work, without fail. Serious injury or death may arise when these checking are neglected. Further, refer to the section of “OPERATION 2.1 Checking before Operation” for the checking of the crane structure.

  • Page 273: Checking After Turning On The Transmitter

    7.1.2 CHECKING AFTER TURNING ON THE TRANSMITTER At the moment when the Transmitter is powered ON, make checks on following items: [1] VERIFICATION OF THE LCD SCREEN SIGN AT POWER-ON Push the Power switch to turn ON the Transmitter. At this moment, confirm the mark as shown below, in the LCD screen.
  • Page 274 [3] VERIFICATION OF THE LCD SCREEN SIGN AT THE “OUTRIGGER MODE” 1. Push the Power switch to once turn OFF the Transmitter. 2. Push the Power switch again to turn ON the Transmitter. The “Crane mark” is displayed in the LCD screen for 2 seconds around.
  • Page 275 5. Manipulate each operation lever and verify that each indication in the LCD screen is correct. 6. To shift to “Extension mode”, push the Speed/Mode button, while the LCD screen shows the “Ground setting mode”. Here, confirm that the “Outrigger Extension mode” is exhibited. NOTES Switching between “Outrigger Extension mode”...

  • Page 276: Checking Receiver

    7.1.3 CHECKING RECEIVER Perform the following inspections: • Check the Control Box (1), Main Switch (2), Monitor display (3), and Receptacle (4) for oily dirt or other soil. Scrub away the dirt with a clean cloth or such, when any. •...

  • Page 277: Checking After Starting Engine

    7.2 CHECKING AFTER STARTING ENGINE Precautions shown in this section must be practiced prior to the day’s work, without fail. Serious injury or death may arise when these inspections are neglected. Further, refer to the section of “OPERATION 2.1 Checking before Operation” for the checking of the crane structure.

  • Page 278: Checking "Outrigger Mode" Operation

    7.2.2 CHECKING “OUTRIGGER MODE” OPERATION The Crane is inoperable in such event where the LCD screen in the Transmitter shows an error message or the Monitor display in the Receiver shows an error code. Without fail, examine the cause of the error and perform appropriate service when any fault is identified,or contact us or our agents for services.
  • Page 279 8. During the control lever manipulation, slowly pull and release the Accelerator lever and confirm that the speed of outrigger action follows the acceleration ratio. 9. Try other outriggers, No. 2 to 4 by the same manipulation and confirm that the outriggers correctly respond to the lever control. Lastly, manipulate all the outrigger operation levers to “Extend (lower)”.

  • Page 280: Checking "Crane Mode" Operation

    7.2.3 CHECKING “CRANE MODE” OPERATION • Ensure that all the outriggers are securely settled, before starting crane operations. Any crane operations where outriggers are improperly used cause the tip of the Crane or other serious accidents. • The Crane is inoperable in such event where the LCD screen in the Transmitter shows an error message or the Monitor display in the Receiver shows an error code.
  • Page 281 9. Using the Hook raising and lowering lever to the “Lower (lower)” area, lower the hook as much as possible. 10. During the Boom telescoping lever manipulation, to the “Extend (upper)” and “Retract (lower)” area respectively, pull the Accelerator lever and check that the boom follows the lever operation.
  • Page 282 15. Keep pushing the Hook Stow/Setting button and pull the Accelerator lever to verify the hook is stowed properly. 6-38...

  • Page 283: Operation

    8. OPERATION • In no event, attempt to disassemble or modify the Transmitter or Receiver, which may cause an electrical shock or a fire. • Avoid to make an impact to the Transmitter by dropping or hitting. A damaged part of the enclosure allows water to enter inside that brings its troubles or failures and cause a serious hazard, such as malfunction or electrical shock.

  • Page 284: Operation In Outrigger Mode

    8.2 OPERATION IN OUTRIGGER MODE • Check smooth and correct actions of each operation lever of the Transmitter, and they smoothly return to each neutral position when the finger is released. • Each operation lever of the Transmitter will be blocked by its stopper when it is moved full. When it is blocked, do not attempt to push more, otherwise it may damage the Transmitter to cause its fault and results a serious accident.

  • Page 285: Outrigger Setting

    8.2.1 OUTRIGGER SETTING 1. In accordance with “IINTERACTIVE REMOTE CONTROL 6.2 Procedure in the Operation Mode”, enter into the “OUTRIGGER MODE”. 2. Push Speed/Mode button in the mode condition of above 1. The operation mode is switched to “Outrigger Extension mode”. 3.

  • Page 286: Outrigger Stowage

    8.2.2 OUTRIGGER STOWAGE 1. In accordance with “IINTERACTIVE REMOTE CONTROL 6.2 Procedure in the Operation Mode”, enter into the “OUTRIGGER MODE”. 2. Turn one of the outrigger operation levers to “Retract (upper)” and pull the Accelerator lever slowly. 3. When the Crane touches the ground, slowly release the acceleration lever, then release the outrigger operation lever to return to its neutral position.

  • Page 287: Operation In Crane Mode

    8.3 OPERATION IN CRANE MODE • Ensure that all the outriggers are properly installed. Where outriggers are improperly installed, it may result a serious hazard, such as a Crane tipping. • During crane operations, always refer to the portable rated total load chart and avoid over-loaded operations.

  • Page 288: Slewing Operation

    8.3.1 SLEWING OPERATION At the slewing operation, actuate the Accelerator lever carefully and always keep in low speed. Also, actuate the Accelerator lever slowly and delicately to avoide abrupt slewing. Such abrupt acceleration or deceleration especially while a load is hung will make a large impact to the Crane and may result a serious hazard such as Crane tipping or damage.

  • Page 289: Hook Raising And Lowering

    8.3.3 HOOK RAISING AND LOWERING • In the event of “Over-hoist alarming” or “Automatic cut out” during the hook raising operation, immediately suspend winding. Otherwise, it may cause a damege to the Crane, or the wire-rope is broken which result dropping of the hook or laod; a serious accident may happen. •...

  • Page 290: Automatic Hook Stow Function

    8.3.5 AUTOMATIC HOOK STOW FUNCTION CAUTION This automatic hook stow function is not available in the “Micro Speed mode” or “Enhanced Speed mode”. To stow the hook, always cancel either the “Micro Speed mode” or “Enhanced Speed mode”. Refer to “INTERACTIVE REMOTE CONTROL 8.3.6 Set-up and Cancel Micro Speed and Enhanced Speed Mode”...

  • Page 291: Set-Up And Cancel Micro Speed And Enhanced Speed Mode

    8.3.6 SET-UP AND CANCEL MICRO SPEED AND ENHANCED SPEED MODE When it is required to operate the Crane in low speed, use the Micro speed mode, which limits the maximum speed of the Crane and facilitates the smoother control in the low speed range. “MICRO SPEED MODE”...
  • Page 292 [3] SETTING TO THE MICRO SPEED MODE Setting to the Micro speed mode requires actual crane operations with the engine running. Before starting the Micro speed mode setting, always ensure that nobody except on business is within the working area. 1.

  • Page 293: Engine Stop And Emergency Stop Procedure

    8.3.7 ENGINE STOP AND EMERGENCY STOP PROCEDURE • For any abnormalities in crane operations, push immediately the Stop/EMO button to stop the engine. Such cases include that the crane operation does not stop though you release your fingers from any of the operation levers or Accelerator lever, or the Crane starts the operation despite that no operation lever is manipulated.

  • Page 294: Checking After Crane Operation

    8.4 CHECKING AFTER CRANE OPERATION • When the operation of the Crane is finished, always turn OFF the Transmitter and Receiver power. • In no occasions except the Crane operations, power of the Transmitter shall not be turned ON. That may cause an un-expected motion of the Crane and result a serious hazard, such that the Crane hit the other person or any object, or the Crane tips.

  • Page 295: Trouble Shooting

    9. TROUBLE SHOOTING 9.1 BEFORE THE TROUBLE SHOOTING “While Crane operates perfectly under manual control, a part or whole functions are un-operable by the remote control.” In such event of failure as above, perform the DIAGNOSIS shown in next pages. CAUTION First, check in accordance with the table below before you start the diagnosis, based on next pages.

  • Page 296: Errors In The Remote Control Devices

    9.2 ERRORS IN THE REMOTE CONTROL DEVICES. • At the error diagnosis, always verify the indications in the Monitor display in the Receiver and the LCD screen in the Transmitter. Then find the suitable error display description in the table below so that the cause is presumed, then, follow the recommended remedy in it.
  • Page 297 Error display Remedy Main cause Transmitter Receiver Transmitter Receiver The Transmitter, internal ―― ―― Devices defective. Maintenance/replace • Power on the • Data error in the memory. Transmitter, again. Transmitter, internal devices defective. ―― • Return operation • Operation levers were not in Maintenance/replace levers and push the the neutral position, when...

  • Page 298: System Specifications

    10. SYSTEM SPCIFICATIONS Items MCT310 Waterproof protection IP65 System configuration Manual and Remote control, both-way LCD monitor panel Operation monitor • Operation status monitor • Battery monitor • Message • Error code Emergency stop equipment Abnormal signal detector unit at the engine start Automatic power cut unit (Automatic Power-OFF) Safety devices Voltage drop limiter...

  • Page 299: Engine And Electric Motor Specifications

    ENGINE AND ELECTRIC MOTOR SPECIFICATIONS 1. PRECAUTIONS (FOR ENGINE AND ELECTRIC MOTOR SPECIFICATION) 7- 2 2. SAFETY LABEL LOCATIONS 7- 3 3. MACHINE EACH SECTION 7- 5 4. OPERATION 7-14 5. LONG-TERM STORAGE 7-21 6. ELECTRIC MOTOR TROUBLESHOOTING 7-22 7. PRINCIPLE SPECIFICATION LIST 7-23 8.

  • Page 300: Precautions (For Engine And Electric Motor Specification)

    1. PRECAUTIONS ( FOR ENGINE AND ELECTRIC MOTOR SPECIFICATION) The following precautions should always be observed when using the machine abiding by engine and electric motor specifications. Potential serious accident may occur if disregarded. • Installation of this machine must comply with laws and regulations of your country. Contact us or our sales service agency if no laws and regulations are applied.

  • Page 301: Safety Label Locations

    2. SAFETY LABEL LOCATIONS Keep these labels clean all the time. If lost, apply again or replace with new one. Labels other than the following safety labels exist, treat same.
  • Page 302 CAUTION The different and supplementary labels are applied to the machine abiding by engine and electric motor specifications, as compared with the standard specification machine. This section describes the labels designed for the machine abiding by engine and electric motor specifications.

  • Page 303: Machine Each Section

    3. MACHINE EACH SECTION 3.1 MACHINE EACH UNIT (1) Boom (17) Operation seat (2) Boom telescoping cylinder (Inside the boom) (18) Instrument panel (3) Boom derricking cylinder (19) Power supply box (4) Load indicator (20) Power unit cover (5) Winch (21) Hook block (6) Post (22) Hydraulic oil tank (Inside machinery cover)

  • Page 304: Traveling And Crane Operation Units

    3.2 TRAVELING AND CRANE OPERATION UNITS (1) Slewing lever (9) Right traveling lever (2) Boom telescoping lever (10) Left traveling lever (3) Winch lever (11) Moment limiter display panel (4) Boom derricking lever (12) Power supply box (5) Outrigger un-set warning lamp (13) Power unit cover (6) Acceleration pedal (14) Instrument panel...

  • Page 305: Instrument Panel Sections

    3.3 INSTRUMENT PANEL SECTIONS (1) Headlight switch (9) Engine and electric motor switch (2) Crane high-speed switch (10) Emergency stop cancel switch (3) Hook stowing switch (11) Fuel gauge (4) Traveling high-speed switch (12) Hour meter (5) Boom stowing switch (13) Pre-heat monitor (6) Horn switch (14) Engine water temperature monitor...
  • Page 306 [1] STARTER SWITCH Always turn the starter switch to the “OFF” position after completing the work. NOTES When inserting the key for the starter switch, slide the cover to the left so that you can see the keyhole of the switch, and then insert the key.
  • Page 307 [4] HOUR METER This meter shows the total running hours of the machine. Use this value as the reference for periodical check interval. With the power lamp of the Inverter unit ON, the meter gives continuous readings upon switching the engine and electric motor switch to “Electric Motor”...

  • Page 308: Power Unit

    3.4 POWER UNIT (1) Power unit cover (2) Electric motor (3) Coupling (4) Hydraulic pump 3.5 POWER SUPPLY BOX (1) Power supply box (2) Power supply box door (3) Door handle (4) Terminal block (5) Cable inserting hole 7-10...

  • Page 309: Inverter Unit

    3.6 INVERTER UNIT (1) Inverter unit cover (5) DC12V power switch (2) Protective cover (6) AC circuit power switch (3) Inverter unit (7) Power lamp (white) (4) Main breaker (with a leak detector) (8) Trouble lamp (red) 7-11...
  • Page 310 [1] MAIN BREAKER (WITH A LEAK DETECTOR) • Make sure the breaker is OFF when this machine derives no power from power supply equipment and when work is completed. • Abnormal conditions are encountered around the Inverter unit, electric motor, or electric wiring when the breaker is automatically turned OFF during operation.
  • Page 311 [2] DC12V POWER SWITCH The DC12V power switch is used to switch the DC power output source for the crane operation system. • ON: Power is supplied to the crane operation system. • OFF: No power is supplied to the crane operation system. [3] AC CIRCUIT POWER SWITCH The AC circuit power switch is used to witch the AC power output source for the Inverter unit and inverter cooling fan.

  • Page 312: Operation

    4. OPERATION 4.1 CHECKING BEFORE OPERATION 4.1.1 CHECKING BEFORE STARTING ELECTRIC MOTOR (VISIBLE CHECKS) For details in checking befor starting engine (visible checks), see “Operation 2.1.1 Checking Before Starting Engine (visible checks)”. As to the machine abiding by engine and electric motor specifications, potential fire in the machine may occur if a heap of flammable materials and oil leak are present around the hot sections such as the Inverter unit, power supply box, and power unit.

  • Page 313: Power Supply Connection

    4.2 POWER SUPPLY CONNECTION (BETWEEN POWER SUPPLY EQUIPMENT AND MACHINE) The following precautions should always be observed. Potential serious accident may occur if disregarded. • Installation of this machine must comply with laws and regulations of your country. Contact us or our sales service agency if no laws and regulations are applied. •...
  • Page 314 3. Remove the cover (6) of the terminal block (5) in the power supply box, holding the top and bottom of the cover (6) with fingers and pulling it toward you. 4. Draw the machine specifications-compliant cabtyre cable (A) through a hole of the cable ground (7) at the bottom of the power supply box to connect it to the terminal block (5).

  • Page 315: Operation And Checking After Power Connection

    4.3 OPERATION AND CHECKING AFTER POWER CONNECTION • Before starting the electric motor, make sure of no presence of personnel around and impediments, and sound a horn. • Warm-up is required. The motor needs adequate warm-up especially in cold climates. Failure to warm the motor may result in serious accident on account of low reactivity of the traveling gear and crane to the operating lever.
  • Page 316 4. Conduct 5-minute warm-up after the electric motor is started. NOTES This machine is structured to switch to the energy-saving mode if no lever operation is attempted within 5 minutes after the electric motor is started. Once the energy-saving mode has been entered, the electric motor undergoes an extreme reduction in rotational speed.

  • Page 317: Machine Operation

    4.4 MACHINE OPERATION CAUTION Perform crane operation referring to “Operation 2.5 Machine Traveling Posture” through “Operation 2.25 Dos and Don’ts during Crane Operations” after motor warm-up is completed. 4.5 MACHINE STOP AND CHECKS AFTER STOPPING MACHINE 1. Turn the starter switch key to the “OFF” position. The electric motor comes to a stop.

  • Page 318: Power Supply Separation

    4.6 POWER SUPPLY SEPARATION (BETWEEN POWER SUPPLY EQUIPMENT AND MACHINE) 1. Turn OFF the power supply equipment breaker. 2. Remove the four mounting screws (11) and remove the protective cover (10). 3. Turn OFF the main breaker (1). 4.Replace the protective cover (10) to the original position and securely tighten four mounting screws (11).

  • Page 319: Long-Term Storage

    5. LONG-TERM STORAGE CAUTION • See “Operation 7. Long-Term Storage” for long-term storage. • This section describes only the long-term storage method that is not defined in standard specifications. Use the following procedure for storing the machine for 6 months or longer (3 months or longer if stored in hot and humid surroundings).

  • Page 320: Electric Motor Troubleshooting

    6. ELECTRIC MOTOR TROUBLESHOOTING • Make sure that you contact us or our sales service agency for the actions indicated in parentheses in the Actions field. • Ask our sales service agency for repair if you suspect other abnormality or causes than those given below.

  • Page 321: Principle Specification List

    7. PRINCIPLE SPECIFICATION LIST System / Item MC-305C-2 (Engine and Electric Motor Specifications) Machine mass 4080kg Overall length  width  4285mm x 1280mm x 1695mm height Mass Distance between idler 1750mm dimensions and sprocket Track gauge 980mm Track width...

  • Page 322: Specification Dimensinal Drawing

    System / Item MC-305C-2 (Engine and Electric Motor Specifications) Model Yanmar 3TNV76 Vertical in-line 3-cylinder, Water cooled, 4-cycle Type (special vortex) Engine Displacement 1.115L (1115cc) Rated output (continuous) 15.2kW/2500min (20.7PS/2500rpm) Fuel tank capacity Light oil/ 40L Battery Model 60B24R (DC12V x 1 piece) Motor specifications Three-phase induction motor: 5.5kW 4P 200.

  • Page 323: Searcher Hook

    SEARCHER HOOK 1. SEARCHER HOOK EACH SECTION 8- 2 2. MOMENT LIMITER DISPLAY UNIT 8- 4 3. OPERATION 8- 6 4. INSPECTION AND MAINTENANCE 8- 8 5. WORKING RADIUS AND RATED TOTAL LOAD 8-11...

  • Page 324: Searcher Hook Each Section

    1. SEARCHER HOOK EACH SECTION (1) Hook (5) Snap pin (2) E-Boom (6) Hex. head bolt (3) Bracket (7) Hex. head nut (4) Position pin (8) High tension washer...

  • Page 326: Moment Limiter Display Unit

    2. MOMENT LIMITER DISPLAY UNIT (1) Boom angle display (14) Working radius upper limit switch (2) Lifting height display (15) Working radius upper limit LED (Orange) (3) Boom length display (16) Over un-winding LED (Orange) (4) Boom lifting height upper limit LED (Orange) (17) Boom angle upper limit switch (5) Boom lifting height upper limit switch (18) Boom angle upper limit LED (Orange)
  • Page 327 [1] DESCRIPTIONS OF SWITCHES ON MOMENT LIMITER DISPLAY UNIT CAUTION Refer “OPERATION 1.6 MOMENT LIMITER” section for switches other than the “WIRE FALLS SELECTOR SWITCH AND WIRE AND WIRE FALLS DISPLAY LED” shown in the next section. 1. WIRE FALLS SELECTOR SWITCH AND WIRE FALLS DISPLAY LED (BLUE) Fall mode must be set as “Searcher hook mode”...

  • Page 328: Operation

    3. OPERATION 1. See “OPERATION 2.14 OUTRIGGER SETTING OPERATION” and set the outrigger. 2. Fasten searcher bracket (3) to main-boom using 4 sets of M12 bolts and nuts. Tighten the bolts with torque wrench (B) them to torque of 93Nm (±13Nm). •...
  • Page 329 6. Insert the position pin (4) through the hole of bracket (3), and ＸＡＭ２９０５０ 新規 secure it with the snap pin (5) to the tip of position pin (4). Always secure the position pin (4) with the snap pin (5). If the snap pin falls out during operations, serious injury or damage to the machine may result.

  • Page 330: Inspection And Maintenance

    4. INSPECTION AND MAINTENANCE 4.1 LEGAL INSPECTION In the event that federal or local law or regulation requires regular inspection to maintain safe operation of machine, check items below: 1. Check disorder of safety devices. 2. Check disorder of lifting equipment such as hook blocks. 3.

  • Page 331: Maintenance Procedures

    4.4 MAINTENANCE PROCEDURES 4.4.1 INSPECTION OF BEFORE OPERATION [CHECKING BEFORE STARTING ENGINE] Check the followings in this section without starting the engine and before starting the first work every day. [1] CHECKING BOOM AND FRAME • Check each part of the boom and frame for cracks, excessive deformation, contamination and others. In addition, check bolts, nuts and pins for any looseness, drop, damage and other matters.
  • Page 332 [CHECKING AFTER STARTING ENGINE] Check the followings in this section after starting the engine and before starting the first work every day. CAUTION The checkups described in this section should be carried out after starting the machine. Refer to "Operation 2.2 Starting Engine" and later to execute the engine startup, traveling operations, outrigger operations and crane operations.

  • Page 333: Working Radius And Rated Total Load

    5. WORKING RADIUS AND RATED TOTAL LOAD • When using the searcher hook, be sure to set searcher hook mode for moment limiter. • Must not use the searcher hook and the crane hook simultaneously. 5.1 WORKING RADIUS AND LIFTING HEIGHT FOR SEARCHER HOOK 8-11...

  • Page 334: Rated Total Load Chart For Searcher Hook

    5.2 RATED TOTAL LOAD CHART FOR SEARCHER HOOK Rated total load Chart 5.945m BOOM 8.145m BOOM 10.315m BOOM 12.485m BOOM Working Rated total Working Rated total Working Rated total Working Rated total radius (m) load (kg) radius (m) load (kg) radius (m) load (kg) radius (m)

  • Page 335: 850Kg Searcher Hook

    850kg SEARCHER HOOK 9- 2 1. SAFETY DECAL LOCATIONS 9- 5 2. SEARCHER HOOK EACH SECTION 9- 6 3. MOMENT LIMITER DISPLAY UNIT 9-10 4. OPERATION 9-14 5. INSPECTION AND MAINTENANCE 9-18 6. WORKING RADIUS AND RATED TOTAL LOAD...

  • Page 336: Safety Decal Locations

    1. SAFETY DECAL LOCATIONS...
  • Page 337 ①102-4608500 ②102-4621200 ③103-4635500 ④103-4635800...
  • Page 338 ⑤103-1165300...

  • Page 339: Searcher Hook Each Section

    2. SEARCHER HOOK EACH SECTION (1) E-Boom (8) Hook (2) Bracket (9) Shackle (3) Bracket 1 (10) Hexagonal bolt with washer (strength 10.9) (4) Bracket 2 (11) Hexagonal bolt with washer (strength 10.9) (5) Pin (12) Hexagonal bolt with washer (strength 10.9) (6) Position pin (13) Nut (strength 10) (7) Linch pin...

  • Page 340: Moment Limiter Display Unit

    3. MOMENT LIMITER DISPLAY UNIT (1) Boom angle display (14) Working radius upper limit switch (2) Lifting height display (Setup / cancel) (3) Boom length display (15) Working radius upper limit LED (Orange) (4) Boom lifting height upper limit LED (Orange) (16) Over un-winding LED (Orange) (5) Boom lifting height upper limit switch (17) Boom angle upper limit switch (setup / cancel)
  • Page 341 3.1 DESCRIPTIONS OF SWITCHES MOMENT LIMITER DISPLAY UNIT See “Operation 1.6 Moment Limiter” for how to operate the moment limiter. 3.1.1 WIRE FALLS SELECTOR SWITCH AND WIRE FALLS DISPLAY LED (BLUE) Fall mode/option mode and searcher hook must be set as “850kg searcher hook mode”. Using 850kg searcher hook other than in 850kg searcher hook mode may prevent activation of the pre-warnings and boom auto-stop even when approaching overload, and thus may result in crane damage or machine tipping that could cause a serious accident.
  • Page 342 3.1.2 CANCEL SWITCH Do not use 850kg searcher hook if actual searcher hook offset position and display of boom length window do not match. Without setting moment limiter to the actual searcher hook offset position, moment limiter may not work properly and thus may result in crane damage or machine tipping and could cause a serious accident.
  • Page 343 Searcher Hook offset position and mode display in boom length window...

  • Page 344: Operation

    (strength 10.9) at torque 27N・m (±8N・m). Crash Hazard. Make sure to torque searcher hook mounting plate bolts to the designated tightening torque. To install searcher hook, always use new genuine Maeda bolts, nuts, and washers. 3. Using fall mode/option selector switch (23), set moment limiter to 850kg searcher hook mode (all LED flashes).
  • Page 345 4. Remove the Linch pin (6) from the end of position pin (5), and remove the position pin (5). 5. Line up the hole (8) in E-boom (7) tip and hole (9) in bracket. 6. Insert the removed position pin (5) (in procedure 4.) through the hole of bracket (9), and secure with lynch pin (6) to the tip of position pin (5).
  • Page 346 9. Insert the position pin (10) through the hole of bracket, and secure with lynch pin (11) to the tip of position pin (10). Always secure the position pin (10) with the lynch pin (11). If the position pin falls out during operations, serious injury or damage to the machine may result.
  • Page 347 12. When operation is auto-stopped by reaching overload during boom lowering or extending operation, first retract boom to recover into safe load range, and then lower boom to ground the load. If boom lift must be operated due to the situation, use boom lift bypass switch (11) to enable the boom lift function.

  • Page 348: Inspection And Maintenance

    Parts for mounting searcher hook are consumable items. Replace them at periodic inspection or before they reach abrasion limits. Replace consumable items regularly, which will produce economical use of this machine. Always replace with a Maeda genuine item. Check parts catalog for correct part number for parts request. [CONSUMABLES LIST]...

  • Page 349: Inspection And Maintenance List

    5.3 INSPECTION AND MAINTENANCE LIST This document only covers 850kg searcher hook kit. For crane body, please refer to “Inspection and Maintenance” and follow its precautions. Inspection and maintenance items Page 5.4.1 INSPECTION BEFORE OPERATION 9-16 [CHECKING BEFORE STARTING ENGINE] 9-16 [1]CHECKING E-BOOM, FRAME AND HOOK 9-16...

  • Page 350: Maintenance Procedures

    5.4 MAINTENANCE PROCEDURES 5.4.1 INSPECTION BEFORE OPERATION [CHECKING BEFORE STARTING ENGINE] Check the following in this section without starting the engine and before starting work every day. [1] CHECKING E-BOOM, FRAME AND HOOK Check each part of the E-Boom, frame and Hook for cracks, excessive deformation and contamination etc.
  • Page 351 "boom angle" and "working radius. If the measured value(s) differ from the moment limiter display value, contact MAEDA or MAEDA sales agency. 8. Lift up load and check if boom extending or boom lowering operation is auto-stopped when overloaded. If the operation is not auto-stopped in overloaded condition, please contact us or our sales service agency and do not use the machine.
  • Page 352 6. WORKING RANGE AND RATED TOTAL LOAD • When using the searcher hook, be sure to set searcher hook mode for moment limiter. • Fall mode/option mode and searcher hook position must be set as “850kg searcher hook mode” when 850kg searcher hook is used. Searcher hook position must be displayed on moment limiter boom length window.
  • Page 353 9-19...

  • Page 354: Rated Total Load Chart For Searcher Hook

    6.2 RATED TOTAL LOAD CHART FOR SEARCHER HOOK 1. This Rated Total Load Chart shows the maximum allowable capacities. These rated total loads are based on the machine standing level on a firm ground supporting surface, under ideal job conditions and a freely suspended load.
  • Page 355 OFFSET POSITION SH1 OFFSET POSITION SH2 OFFSET POSITION SH3 9-21...
  • Page 356 9-22...
  • Page 357 MAEDA MINI-CRAWLER CRANE MC-305C-2 OPERATION MANUAL Document No : 103E-OM1805-08 9th edition : May 31, 2018 Issued by Maeda Seisakusho Co., Ltd. 1095 Onbegawa, Shinonoi Nagano, Nagano 388-8522, Japan No part of this manual can be reproduced in any from without permission...

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